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Cleaver-Brooks
Model CBEX Elite 100-800 HP

Model CBEX Elite 100-800 HP

Product catalog summary

Features and Benefits
The CBEX Elite 100-800 HP Firetube boiler by Cleaver-Brooks is engineered for high efficiency, flexibility, reliability, safety, and ease of operation. It includes a two-pass design, front and rear maintenance access, and supports natural gas, No. 2 oil, or combination burners for quick fuel changeover.

Product Offering
The CBEX boilers are available in a two-pass wetback design with steam pressures of 150, 200, or 250 psig and hot water pressures of 30 and 125 psig. Options include additional tappings, blowdown valves, seismic design, and low NOx equipment.

Dimensions and Ratings
Detailed tables and figures provide dimensions and ratings for steam and hot water boilers, including overall lengths, widths, heights, and weights for different horsepower models.

Performance Data
Efficiency tables show fuel-to-steam efficiencies for natural gas and No. 2 oil, with guarantees on efficiency at various load percentages. Emission levels for CO, NOx, SOx, and other pollutants are estimated for different system configurations.

Specifications
The document outlines specifications for various components of the CBEX Elite Boilers, including safety valves, relief valves, steam volume, and disengaging area. It specifies the number and size of valves required for different boiler HP and pressure settings.

Procedures
Detailed procedures for fuel connections, both gas and oil, are provided, including installation guidelines, pressure requirements, and recommendations for ensuring system integrity and safety.

Standards and Recommendations
The document emphasizes compliance with local codes and standards, particularly concerning blowdown water requirements and boiler room air supply. It also provides guidelines for stack and breeching design to ensure proper draft and burner performance.

Key Tables and Data
Several tables provide critical data such as valve settings, steam volume, recommended nozzle sizes, and gas pressure requirements, essential for ensuring the correct setup and operation of the boilers.

Boiler Room Requirements
The document specifies the necessary dimensions and air supply requirements for boiler rooms, ensuring adequate space and ventilation for optimal boiler operation.

Additional Notes
Notes on altitude corrections, burner characteristics, and the importance of consulting local Cleaver-Brooks representatives for specific installation and operational guidance are included.

Oil Burner Specifications

Oil Pump: Must have a capacity approximately twice the maximum burning rate. The motor-driven pump set is shipped loose for installation near the oil storage tank.
Oil Burner Piping: Includes oil pressure regulating devices, oil metering controls, low oil pressure switch, two motorized oil valves, and pressure gauges, all integrally mounted.
Low Pressure Air Atomizing: Features a separate air compressor module with a burner-mounted low-atomizing air pressure switch.
Burner Turndown: 7:1 when firing No. 2 oil.
Excess Air: 25% with 10 ppm CO.

Gas Burner Specifications

Gas Burner Piping: Includes a primary gas shutoff valve, motor-operated with proof of closure switch, and plugged leakage test connection. The main gas valve closes automatically in case of power failure, flame failure, low water, or any safety shutdown condition. Additional safety features include a lubricating plug cock, high and low gas pressure switches, and a second motorized safety shutoff valve.
Burner Turndown: 10:1 with 15% excess air when firing natural gas. VSD required to maintain 3% O2 over the turndown range.
CO Emissions: 10 ppm at 50% to 100% firing, increasing to 50 ppm CO at 10:1 turndown.

Fuel Series 700 - Gas-Fired

Burner Type: High radiant multi-port type gas entry, approved for natural gas.
Gas Pilot: Premix type with automatic electric ignition and electronic detector.
Gas Burner Piping: Similar specifications as above with additional vent valve between safety shutoff valves.
Burner Turndown: 4:1 when firing natural gas.
CO Emissions: 25 ppm at 50, 75, and 100% firing, 50 ppm at 25% firing rate.

Fuel Series 100 - Light Oil-Fired

Burner Type: Low pressure air atomizing type approved for CS12-48 Commercial No. 2 oil.
Gas Pilot: Similar to Fuel Series 700.
Oil Pump and Piping: Similar specifications as above.
Burner Turndown: 4:1 when firing No. 2 oil.
Excess Air: 25% with 10 ppm CO.

Fuel Series 200 - Light Oil or Gas-Fired

Burner Type: Combination of low pressure air atomizing type for oil and multi-port type for gas.
Gas Pilot: Similar to Fuel Series 700.
Oil and Gas Burner Specifications: Similar to previous series with specific turndown and excess air requirements.

Specifications
The document outlines specifications for burners approved for operation with either CS12-48 Commercial No. 2 oil or natural gas. It includes details on gas pilots, oil burners, and gas burners, specifying components like shut-off valves, solenoid valves, pressure regulators, and leakage test connections.

Gas Pilot
The gas pilot is a premix type with automatic electric ignition. An electronic detector ensures the primary fuel valve opens only after the pilot flame is established. The pilot train includes a manual shut-off valve, solenoid valve, pressure regulator, and a plugged leakage test connection (Canada only).

Oil Burner
The oil burner includes an oil pump with a capacity approximately twice the maximum burning rate. The oil burner piping features oil pressure regulating devices, oil metering controls, low oil pressure switch, motorized oil valves, and pressure gauges. A separate air compressor module is provided for low-pressure air atomizing.

Gas Burner
Gas burner piping includes a primary gas shutoff valve, motor-operated with proof of closure switch, and a plugged leakage test connection. Safety features ensure the main gas valve closes automatically during power failure, flame failure, low water, or any safety shutdown condition. High and low gas pressure switches are included, along with a vent valve between safety shutoff valves.

Burner Turndown and Emissions
The document specifies turndown ranges for different fuel series and conditions, such as 7:1 for No. 2 oil and 10:1 for natural gas. It also details CO emissions, with 10 ppm CO for natural gas with 15% excess air and 25 ppm CO for other conditions.

Fuel Series
The document categorizes burners into different fuel series, such as Fuel Series 700 for gas-fired and Fuel Series 100 for light oil-fired, each with specific burner types and operational approvals.

Fuel Series 200 - Light Oil or Gas-Fired

Burner Type: Combination of low pressure air atomizing for oil and multi-port for gas, approved for CS12-48 Commercial No. 2 oil or natural gas.
Gas Pilot: Premix type with automatic electric ignition and electronic detector to ensure the primary fuel valve opens only after pilot flame establishment. Includes manual shut-off valve, solenoid valve, pressure regulator, and a plugged leakage test connection (Canada only).
Oil Burner:
- Oil Pump: Capacity approximately twice the maximum burning rate, motor-driven, shipped loose for installation near the oil storage tank.
- Oil Burner Piping: Includes oil pressure regulating devices, oil metering controls, low oil pressure switch, two motorized oil valves, and pressure gauges, all integrally mounted.
- Low Pressure Air Atomizing: Separate air compressor module with burner-mounted low-atomizing air pressure switch.
- Burner Turndown: 6:1 when firing No. 2 oil.
- Excess Air: 25% with 10 ppm CO.
Gas Burner:
- Gas Burner Piping: Includes primary gas shutoff valve, motor operated with proof of closure switch, and plugged leakage test connection. Main gas valve closes automatically on power failure, flame failure, low water, or safety shutdown. Includes lubricating plug cock for tightness check, additional plug cock at gas train entrance, high and low gas pressure switches, second motorized safety shutoff valve with plugged leakage test connection, and vent valve between safety shutoff valves. Gas pressure regulator optional.
- Burner Turndown: 6:1 when firing natural gas.
- CO on Natural Gas: 25 ppm with excess air at 25%.

CBEX Elite 100-800 HP

Fuel Series 700 - Gas-Fired:
- Burner Type: High radiant multi-port type gas entry, approved for natural gas.
- Gas Pilot: Premix type with automatic electric ignition and electronic detector. Includes manual shut-off valve, solenoid valve, pressure regulator, and plugged leakage test connection (Canada only).
- Gas Burner Piping: Similar specifications as Fuel Series 200.
- Burner Turndown: 7:1 when firing natural gas.
- CO on Natural Gas: 25 ppm with excess air at 25%.
Fuel Series 100 - Light Oil-Fired:
- Burner Type: Low pressure air atomizing type approved for CS12-48 Commercial No. 2 oil.
- Gas Pilot: Similar specifications as Fuel Series 200.
- Oil Pump: Similar specifications as Fuel Series 200.
- Oil Burner Piping: Similar specifications as Fuel Series 200.
- Low Pressure Air Atomizing: Similar specifications as Fuel Series 200.
- Turndown Range: 7:1 when firing No. 2 oil.
- Excess Air: 25% with 10 ppm CO.

Burner Specifications
The document outlines specifications for burners used in boilers, focusing on both light oil and gas-fired systems. The burners are mounted at the front of the boiler and are designed to operate with either CS12-48 Commercial No. 2 oil or natural gas. The burner types include low pressure air atomizing for oil and multi-port for gas.

Gas Pilot System
The gas pilot is a premix type with automatic electric ignition, monitored by an electronic detector to ensure the primary fuel valve only opens once the pilot flame is established. The pilot train includes a manual shut-off valve, solenoid valve, pressure regulator, and a plugged leakage test connection for Canadian installations.

Oil Burner System
The oil burner system includes an oil pump with a capacity double the maximum burning rate, motor-driven and shipped loose for installation near the oil storage tank. The oil burner piping integrates oil pressure regulating devices, metering controls, a low oil pressure switch, motorized oil valves, and pressure gauges. The system also features a low pressure air atomizing module with a burner-mounted low-atomizing air pressure switch.

Gas Burner System
The gas burner piping includes a primary gas shutoff valve with a proof of closure switch, high and low gas pressure switches, and a second motorized safety shutoff valve. A vent valve is located between the safety shutoff valves, and a gas pressure regulator is optional. The turndown range for natural gas firing is specified as 3:1 or 4:1 depending on the series.

Boiler Controls and Control Panel
The control panel is housed in a NEMA 4/12 rated enclosure, divided into upper and lower sections for low and high voltage components, respectively. The Cleaver Brooks Combustion Control System, Hawk 2000, is used for fuel-air ratio control, and the CB780E Flame Safeguard is integrated into the Hawk control.

Flue Gas Heat Recovery
An optional Cleaver Brooks economizer can be added for flue gas heat recovery, designed for easy installation on the boiler.

Efficiency Guarantee
The boiler is guaranteed to operate at a specified minimum fuel-to-steam efficiency at 100% rating for both natural gas and oil, with details available from a Cleaver-Brooks representative.

Execution and Warranty
The equipment is guaranteed against defects for 12 months from start-up or 18 months from shipment. Factory tests are conducted to check construction, controls, and operation, with start-up services provided by a field representative for training and commissioning.

Fuel Specification and Piping
This section outlines the specifications for different fuel series used in boilers, including gas-fired, light oil-fired, and dual fuel options. It details the burner types, gas pilot systems, and piping requirements for each fuel type. The document specifies NOx emission options (60 ppm, 30 ppm, 9 ppm, 7 ppm) for natural gas and provides guidelines for burner turndown ratios and excess air levels.

Boiler Controls and Control Panel
This section describes the control systems for the boiler, including low water cutoff controls, pressure and temperature gauges, relief valves, and temperature controls. It emphasizes the importance of maintaining safe operating conditions and outlines the components necessary for efficient burner operation.

General Boiler Design
The boiler design is optimized using CFD modeling and features a multipass horizontal firetube updraft configuration. The boiler is preassembled and fire-tested at the factory, ready for installation. It complies with various insurance and code requirements, including ASME and NFPA standards.

Boiler Shell and Components
The boiler shell is constructed according to ASME code and includes features such as a manhole, handholes, and lifting lugs for inspection and maintenance. The design ensures rapid mixing of return water and includes observation ports for flame inspection.

Burner Specifications
The burner incorporates "Lean Burn Technology" and is designed for full modulation operation. It includes a forced draft blower to reduce noise and vibration. The combustion air control system uses individual actuators for precise flame regulation.

Execution and Warranty
This section covers the warranty and shop tests for the boiler, ensuring compliance with quality standards and providing assurance of performance.

Sample Specifications
Cleaver-Brooks provides sample specifications to assist in meeting specific customer needs. These templates serve as a base for complete boiler specifications and include options for special insurance and code requirements.

Specifications
1. Fuel Types: The document outlines specifications for burners that operate on Commercial No. 2 oil or natural gas.
2. Gas Pilot: A premix type with automatic electric ignition and an electronic detector to ensure the primary fuel valve opens only after the pilot flame is established. Includes a manual shut-off valve, solenoid valve, pressure regulator, and a plugged leakage test connection (Canada only).
3. Oil Burner: Features an oil pump with a capacity approximately twice the maximum burning rate, oil pressure regulating devices, oil metering controls, low oil pressure switch, motorized oil valves, and pressure gauges.
4. Gas Burner: Includes a primary gas shutoff valve, motor-operated with proof of closure switch, and a plugged leakage test connection. High and low gas pressure switches are provided, along with a second motorized safety shutoff valve and a vent valve.

Procedures
1. Burner Turndown: The turndown range for oil burners is 7:1 or 8:1, while for gas burners it is 10:1, depending on the model and fuel type.
2. Excess Air: For oil burners, excess air is 25% with 10 ppm CO. For gas burners, excess air is 15% with CO levels at 10 ppm, increasing to 50 ppm at maximum turndown.

Norms and Recommendations
1. Safety Features: The main gas valve is designed to close automatically in the event of power failure, flame failure, low water, or any safety shutdown condition.
2. Installation: The motor-driven pump set for oil burners is shipped loose and should be installed in a location favorable to the oil storage tank.

Key Data from Tables/Charts
- The document provides detailed specifications for different horsepower ranges (100-800 HP) and fuel series (700, 100, 200).
- CO emissions and excess air percentages are specified for various firing rates and turndown ranges.

Specifications

The document outlines specifications for various fuel series and burner types, including light oil and gas-fired systems.
Burners are mounted at the front of the boiler and are designed for either low pressure air atomizing for oil or multi-port type for gas.
Gas pilots are premix type with automatic electric ignition and include safety features such as electronic detectors and manual shut-off valves.

Procedures

Oil pumps have a capacity approximately twice the maximum burning rate and are motor-driven, shipped loose for installation near the oil storage tank.
Fuel oil piping includes pressure regulating devices, metering controls, and safety switches.
Gas burner piping includes primary gas shutoff valves, safety shutoff valves, and pressure switches.

Norms and Recommendations

Turndown ranges vary by fuel type, with 7:1 for No. 2 oil and 10:1 for natural gas.
Excess air levels are specified at 25% for oil and 15% for natural gas, with CO emissions at 10 ppm for both fuels under certain conditions.
Safety features include automatic closure of gas valves in case of power failure or flame failure.

Key Data from Tables/Charts

CO emissions and excess air percentages are critical parameters for evaluating burner performance.
Turndown ratios are essential for understanding the operational flexibility of the burners.

Specifications
The document outlines specifications for various fuel series and burner types used in boilers. It includes details on burner types, gas pilots, oil pumps, and burner piping for both oil and gas-fired systems. The burners are designed for operation with either CS12-48 Commercial No. 2 oil or natural gas, with specific configurations for each fuel type.

Procedures
Each burner system includes a gas pilot with automatic electric ignition and an electronic detector to ensure the primary fuel valve does not open until the pilot flame is established. The pilot train includes a manual shut-off valve, solenoid valve, pressure regulator, and a plugged leakage test connection.

Norms and Standards
The document specifies that the burners must be mounted at the front of the boiler and approved for operation with specified fuels. It also details the inclusion of safety features such as motorized safety shutoff valves, high and low gas pressure switches, and vent valves.

Recommendations
For optimal performance, the document recommends consulting with a Cleaver-Brooks representative regarding high turndown capability based on available gas pressure. It also suggests ensuring proper installation of motor-driven pump sets in locations favorable to the oil storage tank.

Key Parameters
- Turndown range varies from 3:1 to 7:1 depending on the fuel type and series.
- Excess air is maintained at 25% with CO levels at 10 ppm for oil and 25 ppm for natural gas.
- The document emphasizes the importance of safety shutdown conditions and automatic closure of main gas valves in case of power or flame failure.

Limitations
The document specifies that certain components, such as the air compressor module and motor-driven pump sets, are shipped loose and require proper installation.

Best Practices
Ensure all safety features are operational and regularly checked, including the proof of closure switch and leakage test connections. Regular maintenance of oil pressure regulating devices and metering controls is also recommended.

Specifications
The document outlines specifications for various fuel series and burner types used in boilers. It includes details on burner types, gas pilots, and burner piping for both oil and gas-fired systems. The burners are designed for operation with CS12-48 Commercial No. 2 oil or natural gas, with specific turndown ratios and excess air requirements.

Procedures
The document specifies procedures for the installation and operation of burners, including the use of gas pilots with automatic electric ignition and electronic detectors to ensure safety. It also details the piping requirements for both oil and gas burners, including shutoff valves, pressure switches, and leakage test connections.

Standards and Norms
The document adheres to safety standards by including features such as automatic shutoff valves in case of power failure or flame failure, and the use of NEMA-rated enclosures for control panels. It also specifies the use of oil, heat, and moisture-resistant wiring.

Recommendations
Recommendations include consulting with a Cleaver-Brooks representative for high turndown capability based on available gas pressure and considering the optional selection of a Cleaver Brooks economizer for flue gas heat recovery.

Efficiency and Warranty
The boiler is guaranteed to operate at a specified minimum fuel-to-water efficiency when burning natural gas or oil. A warranty is provided against defects in materials and workmanship for a specified period. Factory tests are conducted to ensure the construction, controls, and operation of the unit, with start-up services and training provided by a field representative.

Catalog excerpts

Model CBEX Elite 100-800 HP TABLE OF CONTENTS FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PRODUCT OFFERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIMENSIONS AND RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINEERING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAMPLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 .3 .4 . 10 . 12 . 21 1

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CBEX Elite 100-800 HP FEATURES AND BENEFITS The CBEX Elite 100-800 HP Firetube boiler is designed, manufactured, and packaged by Cleaver-Brooks. All units are factory fire tested and shipped as a package, ready for quick connection to utilities. In addition to the features provided on all Cleaver-Brooks Firetube boilers, the following features apply to the CBEX. Two Pass Design: • The packaged boiler offers high efficiency, flexibility, reliability, safety and ease of operation. Front and Rear Access: • Provides access to front tube sheet and furnace. • Large rear access plug for turnaround and...

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100-800 HP CBEX Elite NEMA enclosures. Remote emergency shut-off (115V). Circuit breakers. Day/night controls. Special power requirements. Low NOx Equipment. • Fuel Options: Gas strainer. Gas pressure gauge. Future gas conversion. Oversized/undersized gas trains. Optional Oil Pumps. DIMENSIONS AND RATINGS Dimensions and ratings are shown in the following tables and illustrations. NOTE: The following information is subject to change without notice. Table 1 - CBEX steam boiler ratings Table 2 - CBEX hot water boiler ratings Figure 1 / Table 3 - CBEX steam boiler dimensions Figure 2 / Table 4 -...

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100-800 HP CBEX Elite PERFORMANCE DATA Efficiency Tables 5 and 6 show predicted fuel-to-steam efficiencies (including radiation and convection losses) for Cleaver-Brooks CBEX firetube boilers. For specific efficiencies on firetube boiler offerings not listed here, contact your local Cleaver-Brooks authorized representative. Cleaver-Brooks offers an industry leading fuel-to-steam boiler efficiency guarantee for CBEX Firetube Boilers. The guarantee is based on the fuel-to-steam efficiencies shown in the efficiency tables and the following conditions. The efficiency percent number is only meaningful...

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CBEX Elite 100-800 HP Emissions Table 6. CBEX Natural Gas Estimated Emission Levels POLLUTANT UNITS CO ppmA 10B lb/MMBtu 25 50 0.0075 0.0075 0.018 0.037 ppmA 60 30 9 7 0.07 0.035 0.0105 0.0082 ppmA 1 1 1 1 0.001 0.001 0.001 0.001 ppmA 8 8 4 4 0.0032 0.0032 0.0016 0.0016 ppmA - - - - lb/MMBtu PM 10B lb/MMBtu HC/VOC5 7 PPM SYSTEM lb/MMBtu SOx 9 PPM SYSTEM lb/MMBtu NOx 60 PPM SYSTEM 30 PPM SYSTEM 0.01 0.01 0.01 0.01 A. ppm levels are given on a dry volume basis and corrected to 3% oxygen (15% excess air) B. 50 ppm CO at low fire up to 300 HP and 10 ppm CO at low fire 350 HP and above Table 7. CBEX...

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CBEX Elite 100-800 HP Burner Characteristics Note that altitude correction and burner changes are required for higher altitudes which may alter dimensions, motor hp and gas pressures. Also 50 Hz applications and low NOx options should be reviewed by the CleaverBrooks authorized representative. Fuel Connections - Gas The local gas company should be consulted for requirements and authorization for installation and inspection of gas supply piping. Installation of gas supply piping and venting must be in accordance with all applicable engineering guidelines and regulatory codes. All connections made...

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100-800 HP CBEX Elite Gas pressure requirements Table 14. Model CBEX Elite, Minimum Required Gas Pressure at Entrance to C-B Supplied Regulator/Gas Valve BOILER HP Combination Regulator and Gas Valve Size (in) PRESSURE REQUIRED ("WC) 100 1.5 12.5 125 1.5 20 150 1.5 27.5 200 1.5 38.5 250 2 41 300 2 55 350 2 75.5 400 2 92 500 2.5 55 600 2.5 79 700 3 80.5 800 3 105 Note: For undersized or oversized gas trains or altitudes above 700 feet, contact your local Cleaver-Brooks representative. Table 15. CBEX altitude correction for gas ALTITUDE (FT) CORRECTION FACTOR ALTITUDE (FT) CORRECTION FACTOR 1000...

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CBEX Elite 100-800 HP Boiler Room Information Table 17 shows typical boiler room width requirements. Table 16. Boiler room width BOILER HP 100125 150200 250300 350400 500600 700800 DIM. "A" 86 88 92 98 102 105 DIM. "B" 120 127 144 151 174 178 A NOTES: 1. Recommended Minimum Distance Between Boiler and Wall. Dimension "A" allows for a clear 42" aisle between the water column on the boiler and the wall. If space permits, this aisle should be widened. 2. Recommended Minimum Distance Between Boilers. Dimension "B" between boilers allows for a "clear" aisle of: 42" - 100-200 HP 48" - 250-400 HP 60"...

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100-800 HP CBEX Elite The air openings are to be 5 feet above floor level. • • • • Air required: 1000 x 10 = 10000 cfm (from 2B above). Air velocity: Up to 7 feet = 250 fpm (from 3 above). Area Required: Area = cfm/fpm = 10000/250 = 40 Sq-ft total. Area/Opening: 40/2 = 20 sq-ft/opening (2 required). Notice Consult local codes, which may supersede these requirements. Stack/Breeching Size Criteria The design of the stack and breeching must provide the required draft at each boiler flue gas outlet. Proper draft is critical to burner performance. Although constant pressure at the flue gas outlet...

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CBEX Elite 100-800 HP Sample Specifications Steam Model CBEX Elite 100-800 HP GENERAL Boiler Characteristics (Steam) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - PRODUCTS General Boiler Design - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Steam Boiler Trim - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Burner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fuel Specification And Piping - - -...

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Model CBEX Elite 100-800 HP

Model CBEX Elite 100-800 HP

Catalog excerpts

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