CleaverBrooks FLX Operation, Service And Parts Manual

MODEL FLX

PACKAGED BOILER

1,500,000 to 12,000,000 Btu/hr

Hot Water and Steam

Fuel: Light Oil, Gas or Combination

Manual Part No. 750-177 R5

10/2009

MODEL FLX

PACKAGED BOILER

Operation, Service, and Parts Manual

1,500,000 to 12,000,000 Btu/hr

Fuel: Light Oil, Gas or Combination

Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative

Manual Part No. 750-177 R5

Revised 10/2009

Printed in U.S.A.

WARNING

DANGER

DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.

TO: Owners, Operators and/or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who are servicing, repairing or operating the equipment, in all safety aspects.

Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating techniques and maintenance procedures must be followed at all times. Although these components afford a high degree of protection and safety, operation of equipment is not to be considered free from all dangers and hazards inherent in handling and firing of fuel.

Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before attempting to operate, maintain, service, or repair this equipment.

Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary considerably from one boiler to another. This manual contains information designed to show how a basic burner operates.

Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and deficiencies in testing and maintenance.

It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly maintenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.

Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the need for the operator to periodically check his low water controls and to follow good maintenance and testing practices. Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected frequently to check for the presence of any mud, sludge, scale or corrosion.

The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices are essential.

The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or regulations of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

TABLE OF CONTENTS

Chapter 1

Basics of Flexible Watertube Operation

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

B. The Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

E. Hot Water Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2

ProFire™ V Burner

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Startup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35

Burner Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Chapter 3

Pressure Vessel Care

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

B. Hot Water Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

C. Water Requirements (Steam Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

D. Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

E. Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

F. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

G. Boilout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

H. Washing Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

I. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

J. Preparation For Extended Lay-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Chapter 4

Sequence Of Operation

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

B. Circuit And Interlock Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

C. Sequence Of Operation - Oil Or Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

D. Flame Loss Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

TABLE OF CONTENTS(continued)

Chapter 5

Adjustment Procedures

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

B. Linkage - Modulating Motor & Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

C. Modulating Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

D. Modulating Motor Switches Low Fire and High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

E. Burner Operating Controls - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

F. Modulating Pressure Control (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

G. Operating Limit Pressure Control (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

H. High Limit Pressure Control (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

I. Modulating Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

J. Operating Limit Temperature Control (Hot Water). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

K. High Limit Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

L. Low Water Cutoff Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

M. Combustion Air Proving Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

N.Gas Pilot Flame Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

O. Gas Pressure and Flow Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

P. Gas Fuel Combustion Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Q. Low Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

R. High Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

S. Fuel Oil Pressure and Temperature - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

T. Fuel Oil Combustion Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

U. Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Chapter 6

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

iii

TABLE OF CONTENTS(continued)

Chapter 7

Inspection And Maintenance

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

B. Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

C. Fireside Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

D. Upper Pass Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

E. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

F. Oil Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

G. Gas Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

H. Refractory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

I. Casing Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

Chapter 8

Casing HW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Casing Low Pressure Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Casing High Pressure Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

Steam Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8

Water Level Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

Water Column, Main and Aux. - 15# Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

Water Column, Main and Aux. - 150# Steam. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12

CHAPTER 1

GENERAL DESCRIPTION

A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

B. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . 1-2

E. Hot Water Controls (All Fuels) . . . . . . . . . . . . . . . . 1-4

A. General

The information in this manual applies directly to CleaverBrooks FLX Model boilers in sizes ranging from 1,500,000 to 12,000,000 Btu/hr input.

Fuel Series

700- Gas

100-No.2 0il

CAUTION

DANGER

The care taken in placing the boiler into initial service is vital to continuous, reliable operation. If the boiler is to be used for temporary heat (for example in new construction), properly treated water must be used. Failure to do so can be detrimental to the boiler.

200 - Combination Gas & No.2 Oil

Design Pressure

160 psig hot water

15 psig steam

150 psig steam

750-177 1-1

Figure 1-1: FLX Cut Away

Chapter 1 GENERAL DESCRIPTION

B. The Boiler

The Cleaver-Brooks Model FLX is a five-pass steel boiler with flexible watertubes formed and arranged so as to direct the flow of combustion gases through the boiler. The pressure vessel conforms to Section I or IV of the ASME code. The pressure vessel consists of the formed tubes, the external downcomer, and the top and bottom drums to which they connect. The heated area of the pressure vessel is contained within a gas tight insulated casing that is composed of removable formed steel panels.

Always order genuine Cleaver-Brooks parts from your local Cleaver-Brooks authorized representative.

The boiler and related equipment installation are to be in compliance with the standards of the National Board of Fire Underwriters. Installation should also conform to state and local codes governing such equipment. Prior to installation, the proper authorities having jurisdiction are to be consulted, permits obtained, etc. All boilers in the above series comply, when equipped with optional equipment, to Industrial Risk Insurers (IRI), Factory Mutual (FM), or other insuring underwriters requirements.

The Model FLX boiler is a packaged watertube boiler of welded steel construction and consists of a pressure vessel, burner, burner controls, forced draft fan, damper, refractory, and appropriate boiler trim.

The type of service that your boiler is required to provide has an important bearing on the amount of waterside care it will require.

CAUTION

DANGER

Waterside care is of prime importance. For specific information or assistance with your water treatment requirements, contact your Cleaver-Brooks service and parts representative. Failure to follow these instructions could result in equipment damage.

Feedwater equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and receivers are installed in accordance with prevailing codes and practices.

Water requirements for both steam and hot water boilers are essential to boiler life and length of service. Constant attention to water requirements will pay dividends in the form of longer life, less down-time, and prevention of costly repairs. Care taken in placing the pressure vessel into initial service is vital. The waterside of new boilers and new or remodeled steam or hot water systems may contain oil, grease or other foreign matter. A method of boiling out the vessel to remove accumulations is described in Chapter 3.

The operator should be familiar with Chapter 3 before attempting to place the unit into operation.

Hot water is commonly used in heating applications with the boiler supplying water to the system at 180 °F to 220 °F. The operating pressure for hot water heating systems usually is 30 psig to 125 psig.

Steam boilers are designed for low and high pressure applications. Low pressure boilers are limited to 15 psig design pressure, and are typically used for heating applications. High pressure boilers are limited to 150 psig design pressure, and are typically used for process steam applications.

Steam and hot water boilers are defined according to design pressure and operating pressure. Design pressure is the maximum pressure used in the design of the boiler for the purpose of calculating the minimum permissible thickness or physical characteristics of the pressure vessel parts of the boiler. Typically, the safety valves are set at or below design pressure. Operating pressure is the pressure of the boiler at which it normally operates. The operating pressure usually is maintained at a suitable level below the setting of the pressure relieving valve(s) to prevent their frequent opening during normal operation.

C. Construction

Steam boilers designed for 15 psig and hot water boilers designed for 250°F at 160 psi or less are constructed in accordance with Section IV, Heating Boilers, of ASME Code. Steam boilers designed for 150 psig are constructed in accordance with Section I, Power Boilers, of the ASME Code.

D. Steam Controls (All Fuels)

1. Operating Limit Pressure Control (Figures 1-2 and 1-3): Breaks a circuit to stop burner operation on a rise of boiler pressure at a selected setting. It is adjusted to stop or start the burner at a preselected pressure setting.

2. High Limit Pressure Control (Figure 1-2 and 1-3): Breaks a circuit to stop burner operation on a rise of pressure above a selected setting. It is adjusted to stop the burner at a preselected pressure above the operating limit control setting. The high limit pressure control is equipped with a manual reset.

1-2 750-177

GENERAL DESCRIPTION Chapter 1

3. Modulating Limit Pressure Control (Figure 1-2 and 1-3): Senses changing boiler pressures and transmits the information to the modulating motor to change the burner firing rate when the manual-automatic switch is set on “automatic.”

4. Low Water Cutoff and Pump Control (Figure 1-2, 1-4 and 1-5): Float-operated control responds to the water level in the boiler. It performs two distinct functions:

•Stops firing of the burner if water level lowers below the safe operating point. Energizes the low-water light in the control panel; also causes low-water alarm bell (optional equipment) to ring. Code requirements of some models require a manual reset type of low-water cutoff.

•Starts and stops the feedwater pump (if used) to maintain water at the proper operating level.

CAUTION

DANGER

Determine that the main and auxiliary low water cutoffs and pump control are level after installation and throughout the equipment’s operating life. Failure to f ollow these instructions could result in equipment damage.

5. Water Column Assembly (Figure 1-2): Houses the lowwater cutoff and pump control and includes the water gauge glass, gauge glass shutoff cocks.

6. Water Column Drain Valve (Figure 1-2): Provided so that the water column and its piping can be flushed regularly to assist in maintaining cross-connecting piping and in keeping the float bowl clean and free of sediment. A similar drain valve is furnished with auxiliary low-water cutoff for the same purpose.

7. Gauge Glass Drain Valve (Figure 1-2): Provided to flush the gauge glass.

8. Safety Valve(s) (Figure 1-6 and 1-8): Prevent buildup over the design pressure of the pressure vessel. The size, rating and number of valves on a boiler is determined by the ASME Boiler Code. The safety valves and the discharge piping are to be installed to conform to the ASME code requirements. The installation of a valve is of primary importance to its service life. A valve must be mounted in a vertical position so that discharge piping and code-required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area. Apply only a moderate amount of pipe compound to male threads and

WATER COLUM N

LOW WATER CUTOFF AND PUMP CONTROL

CONTROL PANEL

FLAME

DETECTOR

FORCED DRAFT

FAN MOTOR

GAUGE GLASS

DRAIN VALVE

WATER COLUMN

DRAIN VALVE

MODULATING

MOTOR

HIGH LIMIT PRESSURE

OIL SUPPLY

PRESSURE

GAUGE

OPERATING LIMIT PRESSURE CONTROL

MODULATING LIMIT PRESSURE CONTROLCONTROL

STEAM PRESSURE

GAUGE

750-177 1-3

OIL SOLENOID

VALV ES

OIL PUMP

Figure 1-2: Typical Steam Boiler - Light Oil Fired

Chapter 1 GENERAL DESCRIPTION

avoid overtightening, which can distort the seats. Use only flat-jawed wrenches on the flats provided. When installing a flange-connected valve, use a new gasket and

1. HIGH LIMIT PRESSURE CONTROL

2. OPERATING LIMIT PRESSURE CONTROL

3. MODULATING PRESSURE CONTROL

Figure 1-3: Steam Controls

draw the mounting bolts down evenly. Do not install or remove side outlet valves by using a pipe or wrench in the outlet.

WARNING

DANGER

Only properly certified personnel such as the safety valve manufacturer’s certified representative can adjust or repair the boiler safety valves. Failure to follow these instructions could result in serious personal injury or death

E. Hot Water Controls (All Fuels)

Figure 1-4: Low Water Cut Off (LWCO)

1. Water Temperature Gauge (Figure 1-7): Indicates the boiler internal water pressure.

2. Water Pressure Gauge (Figure 1-7): Indicates the internal pressure of the boiler.

3. Operating Limit Temperature Control (Figure 1-7): Breaks a circuit to stop burner operation on a rise of boiler temperature at a selected setting. It is adjusted to

Figure 1-5: Low Water Cut Off Pump Control

(Cutaway)

1-4 750-177

Figure 1-6: Safety Valve Cutaway

GENERAL DESCRIPTION Chapter 1

stop or start the burner at a preselected operating temperature.

4. High Limit Temperature Control (Figure 1-7): Breaks a circuit to stop burner operation on a rise of temperature at a selected setting. It is adjusted to stop burner at a preselected temperature above the operating control setting. The high limit temperature control is equipped with a manual reset.

5. Modulating Temperature Control (Figure 1-7): Senses changing boiler water temperature and transmits the information to the modulating motor to change the burner firing rate when the manual-automatic switch is set on “automatic.”

6. Low Water Cutoff (Figure 1-7): Breaks the circuit to stop burner operation if the water level in the boiler drops below safe operating point, activating low-water light and optional alarm bell if burner is so equipped.

7. Auxiliary Low Water Cutoff (Not Shown) (Optional): Breaks the circuit to stop burner operation if the water

level in the boiler drops below the master low-water cutoff point.

WATER PRESSURE

GAUGE

WATER TEMPERATURE GAUGE

LOW WATER CUTOFF PROBE

1. High Limit Temperature Control

2. Operating Limit Temperature Control

3. Modulating Temperature Control

4. Low Water Cutoff Control

750-177 1-5

Figure 1-7: Hot Water Controls

Chapter 1 GENERAL DESCRIPTION

SUPPORT FROM BUILDING

DISCHARGE OPENING MUST BE EQUAL TO OR LARGER THAN INLET

DRIP ELL DRAIN

SAFETY VALVE

NOTICE: BACK-PRESSURE OF STEAM EXHAUST SYSTEM MUST BE LESS THAN 6% OF SAFETY VALVE SETTING.

WATER LEVEL

CONSTRUCTION

CAUTION VENT PIPE MUST NOT TOUCH DRIP PAN EXTENSION

TO STEAM

VENT

VENT PIPE

DRIP PAN

EXTENSION

AND ELBOW

OPEN DRAIN

TO WASTE

BOILER SHELL

Figure 1-8: Recommended Piping For Steam

Relief Valve (Not furnished by Cleaver-Brooks)

DRIP PAN

1 1/2”

MIN.

DRIP PAN

DRAIN

remove side outlet valves by using a pipe or wrench in the outlet.

WARNING

DANGER

Only properly certified personnel such as the relief valve manufacturer’s certified representative can adjust or repair the boiler relief valves. Failure to follow these instructions could result in serious personal injury or death.

1-6 750-177

CHAPTER 2

Profire V Burner

A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

B. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

C. Startup and Operation . . . . . . . . . . . . . . . . . . . . . . .2-17

D. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22

E. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

F. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

G. Burner Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39

A. Introduction

CB Profire V/Series burners are assembled, wired, and tested at the factory. The V/Series burner line is listed by the Underwriters Laboratory for the U.S. and Canada, and bears the UL and cUL markings when ordered as such by the customer. Compliance with other regulatory agencies such as CSD-1, I.R.I./GE GAP, F.M., etc., is available at time of order.

Optional controls and control systems are also available. The operator of this equipment must be familiar with the individual functioning of all controls to understand the operations and procedures described in this manual, and supplementary instructions provided with optional controls. Identify and locate each item in the illustrations as they are described in the following sections.

The burners are available in the following configurations:

SIZE 1 - V13-34 - On-Off (Optional: Low-High-Off, LowHigh-Low, Full Modulation)

SIZE 2 - V35-55 - Low-High-Off (Optional: Low-High-Low, Full Modulation)

SIZE3 - V60-63 - Low-High-Off (Optional: Low-High-Low, Full Modulation)

SIZE 3 & 4 - V70-168 - Full Modulation

OPERATING CONTROLS - PANEL

The burner control panel may be integral to the burner or remote, and contains a flame safeguard programming control, motor relays (starters), and terminal strips mounted internally on a panel subbase. Lights, switches, and a control circuit breaker are mounted externally on the panel.

1. ON-OFF BURNER SWITCH

2. FUEL SELECTOR SWITCH - Gas-Off-Oil

Gas position: Selects gas as the firing fuel Off position: Burner off Oil position: Selects oil as the firing fuel

3. CONTROL CIRCUIT BREAKER

Supplementary low overcurrent protection only. No larger than 15 amps.

CAUTION

DANGER

ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST, OR SERVICE THIS EQUIPMENT.

DESCRIPTION

The CB Profire V/Series burners are designed to operate with natural gas and light oil. The burners are designed for automatic, unattended operation except for periodic inspection and maintenance. The control panel components require little attention except for occasional cleaning.

750-177 2-1

4. AUTO-MANUAL MODULATION SELECTOR SWITCH

Auto position: Selects boiler modulation control. In this position, the burner will operate automatically in response to load demand. Manual position: Selects 135 ohm potentiometer for manual modulating control.

5. MANUAL MODULATING CONTROL - 135 ohm

(For full modulation burner only.) Increases or decreases the burner firing rate.

6. SIGNAL LAMPS

a. POWER ON (white) - Illuminates when the control circuit is energized (powered). b. IGNITION (amber) - Illuminates when the ignition

2-1

Chapter 2 Profire V Burner

transformer is powered, and pilot valve is energized (open). c. MAIN FUEL (green) - Illuminates when the main fuel valve or valves are energized (open). d. FLAME FAILURE (red) - Illuminates when the flame safeguard system fails to detect pilot or main flame.

7. MODULATING MOTOR

Operates the air damper and fuel rate valves through a linkage system to adjust air-fuel ratios under all load conditions.

8. IGNITION TRANSFORMER

Provides high voltage spark for ignition of gas pilot or main flame direct spark models.

FLAME SAFEGUARD CONTROLS

The flame safeguard controls the operating sequence of the combustion system (pre-purge, pilot, firing, and shutdown). The flame safeguard programmer incorporates a flame sensing cell (scanner) to shut down the burner in the event of pilot flame or main flame failure. Other safety controls shut down the burner based on sequence of operation as shown in the manufacturer’s flame safeguard manual.

When a parallel positioning system is furnished, the flame safeguard may be incorporated as an integral component to the parallel positioning control. Consult burner and component technical documentation.

air flow with the fuel flow provides efficient combustion at all firing rates.

OIL SYSTEM

Models Vl-VLG are high pressure atomizing burners using fuel pressure for atomization. Atomized fuel is discharged from the nozzle as a fine conical spray.

1. FUEL UNIT - Size 1 & 2

Direct driven from the blower motor with a flexible coupling at 3450 rpm, and set for 300 psi operation, fuel unit is two stage (two sets of gears) and must be installed for a two pipe installation, one suction and one return line. Separately driven oil pumps are available as options to the standard arrangement.

Size 3 & 4

A separately driven oil pump is standard.

2. NOZZLE

The nozzle meters oil flow delivering a specified amount at a specific pressure. Fuel pressure (mechanical) atomizes oil in a fine conical spray pattern from the nozzle orifice. The

ABC

burner is supplied with nozzle(s) to fire to its maximum rate unless a different firing rate was specified. VL and VLG models 13-34 supplied with simplex nozzles, models 35-168 are supplied with return flow nozzles.

3. NOZZLE ADAPTOR

EFG

COMBUSTION AIR HANDLING SYSTEM

1. MOTOR AND BLOWER

The impeller is directly driven by the motor at 3450 rpm. A heavy duty forward curved, multi-blade centrifugal impeller supplies combustion air.

2. AIR VOLUME REGULATOR

Air dampers are located in the air inlet housing. The dampers are mechanically linked and actuated by a two-position motor or hydraulic cylinder for on-off operation. Low-high-off, low-high-low, or full modulation burners have the dampers mechanically linked to the modulating motor.

3. COMBUSTION AIR PROVING SWITCH

A pressure sensitive, differential switch actuated by air pressure created by the blower fan. Contacts close to prove combustion air flow.

4. DIFFUSER

An air flow diffuser stabilizes flame front.

OPERATION: Air from the impeller flows through the blast

tube and diffuser to mix with fuel in the ignition zone. Combustion air flow rate is determined by the position of the air regulating blades at the inlet of the impeller. Linking the

The nozzle adaptor provides the means for connecting fuel lines with the nozzle.

4. OIL SOLENOID VALVES

Two normally closed (N.C.) and one normally open (N.O.) solenoid valves are part of the oil system on LO-HI-OFF and

LO-HI-LO burners. The two N.C. valves provide positive shutoff of fuel oil while the one N.O. valve cycles the burner to HI fire when closed.

5. OIL METERING VALVE

The firing rate is controlled by an adjustable metering valve in the return line. At low fire, the metering valve is open, and is closed at high fire.

6. OIL FILTER

Prevents foreign matter from entering the burner oil system. This item is provided optional and shipped loose with burner.

OPERATION: Fuel oil is delivered to the fuel unit, either by

gravity, fuel unit suction, or by a circulating pump, through a fuel oil filter. Pressurized fuel returns to the storage tank until the two solenoid valves open. On direct spark ignited burners (VL-13 to 55) ignition occurs when the oil valves open. Where gas pilots are provided (models VG and VLG), the oil valves open after the pilot is proven. Oil input rate is controlled by the oil metering valve, which varies the flow to

2-2 750-177

Profire V Burner Chapter 2

meet load demands. The low fire positions bypass oil back to the storage tank. At high fire, the metering valve is in the closed position. The modulating motor positions the metering valve and the air damper simultaneously.

IGNITION SYSTEM

Oil only models VL-13 to 55 are supplied with direct spark ignition. Models VL-60 to 168 are supplied with a gas pilot system. Gas and combination gas-oil models are supplied with a gas ignition system. The standard pilot gas train consists of a manual shutoff cock, a gas pressure regulator, and a solenoid operated gas shutoff valve.

GAS HANDLING SYSTEM

Depending upon the requirements of the regulating authority, the gas control system and gas train may consist of some, or all, of the following items:

1. GAS VOLUME VALVE

The butterfly type valve is positioned by linkage from the modulating motor and control the rate of flow of gas.

2. MAIN GAS VALVES

Electrically operated safety shutoff valve(s) that open to admit gas to the burner. Standard U.L. burners include:

A pressure actuated switch that remains closed when gas pressure is above a selected setting. Should the pressure drop below this setting, the switch contacts will open, causing main gas valve(s) to close. This switch requires manual reset after being tripped.

OPERATION: Metered gas flows through the main gas

shutoff cock, through the pressure regulators to the automatic gas valves and butterfly valve to the gas manifold. The butterfly gas valve modulates flow to burner input demand. The butterfly valve is positioned through mechanical linkage by the modulating motor. The air control damper is positioned simultaneously by the modulating motor. The automatic gas valve(s) cannot be energized unless the combustion air proving switch is closed. The low and high gas pressure switches must be closed to prove proper gas pressure.

A normally open vent valve, if required, is located between the two automatic gas valves. This valve is shut when the automatic gas valves are open. When the automatic valves are closed, the vent valve is open for venting gas to the outside, should any be present.

Notice: Gas train components upstream of the

butterfly valve are shipped loose to be mounted by the installer.

• Models 13-25: Diaphragm gas valve & solenoid valve.

• Models 30-50: One motorized gas valve w/proof of closure or two safety shutoff valves.

• Models 55-120: One motorized gas valve w/proof of closure and one safety shutoff valve.

• Models 126-168: Two motorized gas valves.

(Two motorized gas valves can be optionally provided on all models.)

3. MAIN GAS REGULATOR

Regulates gas train pressure to specified pressure required at the burner manifold. Input is set by main gas pressure regulator adjustment.

4. MAIN GAS COCKS

Used for manual shutoff of the gas supply upstream of the pressure regulator. A second shutoff cock downstream of the main gas valve(s) provides a means of testing for leakage through the gas valve(s).

5. HIGH GAS PRESSURE SWITCH (Models 30-168)

A pressure actuated switch that remains closed when gas pressure is below a selected setting. Should the pressure rise above the setting, the switch contacts will open causing main gas valve(s) to close. This switch requires manual reset after being tripped.

Notice: Pilot gas supply connection must be

upstream of the main gas pressure regulator.

6. LOW GAS PRESSURE SWITCH (Models 30-168)

750-177 2-3

Chapter 2 Profire V Burner

Figure 2-1: Profire Burner

Figure 2-2: Interior Burner Components

Figure 2-2: Burner-Cutaway View

2-4 750-177

Profire V Burner Chapter 2

BURNER

MODEL A B C D E F

SIZE 1

SIZE 2

SIZE 3

SIZE 4

32 7/8 12 3/8

37 1/3 13 5/8

44 3/8 16 1/8

54 3/8 24 7/8

8 1/4 3 3/4

4104

11 1/2 3 3/4 17 1/2 15 3/4 41 3/4 15 1/4 7 3/8 16 3/4 15 1/4 8 3/8 17 3/8 12 1/2 14 1/8 6 1/4 10 1/4 18 5/8

13 5/8

B. Installation

K DIA.

STANDARD CONFIGURATION - REAR MOUNTED PANEL, GAS PILOT LINE PANEL MOUNTED

18 1/8

25 1/4

H I

9 3/4

34 1/2 10 1/2 7 3/8

45 7/8 13 1/2 7 3/8 17 1/2 15 3/8 8 3/4 20 1/8 14 1/2

K L M N P R S T

9 3/4 7 3/8 12 7/8 11 1/4 6 1/2 14 3/8

13 1/4 7 1/2 15 1/8 12 1/2 12 3/4 6 1/4

Figure 2-3: Burner Dimensions (Inches)

Consult with insurance carrier and/or local authorities for specific regulations.

4X Ø3/4 L B.C.

656-00037

5 /14 7 1/4 11 3/4

7 1/2 12 1/4 19 1/4

14 1/2

DRAFT CONDITIONS

A boiler or other heating vessel fired with a V Series burner does not depend on chimney draft for proper combustion air. Combustion air is supplied by the burner forced draft blower providing adequate air for any normal combustion condition.

Since draft control is essential to maximum efficiency, a draft regulator may be required when the vessel is connected to a tall stack or where wind conditions may cause erratic draft. Excessive furnace draft contributes to inefficient burner operation.

Sealed boilers may be operated under positive firebox pressure within the capability of the burner.

COMBUSTION AIR SUPPLY

The space in which a burner operates must be supplied with adequate fresh air for combustion and ventilation purposes. Fresh air supply must meet or exceed all code requirements.

WARNING

DANGER

CAUTION

DANGER

THE BOILER ROOM PRESSURE MUST BE AT LEAST EQUAL TO THE OUTDOOR A TMOSHERIC PRESSURE. WHERE FAN VENTILATION IS USED, AIR MUST BE FORCED INTO THE BOILER ROOM. NEVER EXHAUST AIR FROM THE BOILER ROOM. ADJOINING AREAS HAVING EXHAUST FANS MUST BE POSITIVELY ISOLATED FROM THE BOILER ROOM.

COMBUSTION CHAMBER DESIGN

The V series burners are of the forced draft flame retention type. Refractory is required only to protect surfaces not adequately protected by free circulating water. Four basic objectives are:

• Provide adequate combustion space

• Avoid flame impingement

• Protect surfaces not adequately water cooled

• Seal openings

The table below shows suggested minimum combustion chamber dimensions.

750-177 2-5

Chapter 2 Profire V Burner

Suggested Minimum Combustion Chamber Dimensions

While these dimensions are typical for good practice, satisfactory results may be achieved with modifications to suit some conditions. Factors such as fuel properties, total combustion volume, length of flame trave often make fixed requirements impractical. When in doubt, consult the factory.

Insulation should be provided between the refractory and the boiler base. Mineral wool, or other material not likely to settle is preferred. The chamber front wall may be constructed of firebrick or insulating firebrick. Insulation should be used between refractory and front plate. Firebrick, or insulating firebrick should be set in high temperature bonding mortar with provision for expansion.

CAUTION

DANGER

THE GASKET MUST BE RESILIENT TO SEAL ANY UNEVEN AREAS BETWEEN THE BURNER FLANGE AND THE BOILER FRONT PLATE TO PREVENT LEAKAGE OF COMBUSTION GASSES.

Suggested Minimum Combustion Chamber Dimensions are based on the rated capacity of the burner.

Figure 2-7: V Burner Installation, Commercial Watertube Boiler

2-6 750-177

Profire V Burner Chapter 2

GAS PIPING

Gas service and house piping must supply the quantity of gas demanded by the unit at the pressure required at the burner gas train inlet.

All piping must be in strict accordance with applicable codes, ordinances and regulations of the supplying utility. In the absence of other codes, piping should be in accordance with the following standards: “National fuel Gas Code” NFPA No. 54, ANSI No. Z223-1.

Gas train components upstream of the butterfly valve are shipped loose. These components should be mounted by the installer as close to the butterfly valve as practical.

Normally, the control train is ordered to suit a particular code or insurance regulation - such as Underwriters Laboratories/ Canadian Underwriters Laboratories (UL/cUL), Factory Mutual, or Industrial Risk Insurance.

Arrange gas piping at the burner so that the burner is accessible for servicing without disassembly.

The pilot gas train is supplied with the burner, and is factory installed. The gas pilot supply line must be connected upstream of the main gas regulator. If a reducing bushing is required between the house piping and the burner piping, it should be close to the burner shutoff valve.

The gas piping must be internally clean and free of foreign material. Before using in service, a leak test must be performed.

FUEL OIL PIPING

PRESSURE ATOMIZATION OIL PIPING

The VL and VLG model burners use pressure atomization. Fuel oil is provided by a burner mounted fuel unit directly coupled to the blower motor via a flexible coupling on Size 1 & 2 burners, Remote Pump on Size 3 & 4 burners. The suction and return line sizes (two-pipe system) are based on the suction rate of the fuel unit and not the burner firing rate. Pipe size must be selected sot that suction vacuum is within suitable limits.

TWO PIPE - SINGLE BURNER OPERATION

A two-pipe system is essential. The suction and return between the storage tank or supply source and the burner must be sized to supply the required quantity of oil circulated, including excess oil returned to the storage tank.

SUCTION LINE SIZING

The Suction load is determined by:

1. The vertical lift from the oil level in the tank to the pump.

2. Pressure drop through valves, fittings, strainers, etc.

a. Quantity of oil pumped (gph). b. Length of suction line (feet). c. Diameter of the suction line. d. Number of fittings.

Although the gear type pumps used on the V series burners are capable of developing higher suction, it is not desirable to operate above 15 inches of mercury vacuum. If the vacuum is greater, flow may be erratic.

Refer to the manufacturer’s table for line sizing.

1. Check suction capacity.

2. Measure total pipe length (horizontal and vertical).

3. Read up from line “total feet of copper tube” to the intersection line of the specific “suction capacity” in gph.

4. Read left to column “inches of vacuum at fuel unit.” This is vacuum required to draw oil through pipe listed at given length.

5. Add 1” of vacuum for every foot of lift.

6. Total inches of vacuum (frictional tube loss plus lift).

7. If total exceeds 15”, check next larger pipe size.

RETURN LINE SIZING

Generally, the return line should be sized the same as the suction line.

TWO PIPE - MULTIPLE BURNER SYSTEM

Several options exist for a multiple burner installation.

The circulating pump is sized for the total suction capacity of all burners. Note that a special pressure regulating valve is required if the fuel unit inlet pressure is above 3 psi.

Depending on configurations:

• separate suction lines for each burner with a common

return line

• multiple burners with oil supplied by a transfer pump

• a pump supplies oil to the day tank

• flooded loop system - the circulating pump is sized

according to the maximum burner firing rate for all burners plus a 30% service factor

Notice: CB Profire recommends that all oil firing burners be equipped with an oil strainer (if not included with the burner) to prevent particles from clogging the nozzle. It is essential to follow the strainer manufacturer’s maintenance schedule to ensure proper filtration.

3. The friction loss due to oil flow. This loss varies with:

750-177 2-7

Chapter 2 Profire V Burner

Figure 2-11: Typical UL Gas Train, Full Modulation System, Size 1 V13 to V34

Figure 2-12: Typical UL Gas Train, Low-High-Off/Low-High-Low, Size 2 V35 to V63, Full Mod System, Size 2-3-4 V35 to V168

2-8 750-177

Profire V Burner Chapter 2

750-177 2-9

Figure 2-13: Oil System Configurations

Chapter 2 Profire V Burner

Figure 2-14: Multiple Burners Configurations

Figure 2-15: Day Tank

2-10 750-177

Profire V Burner Chapter 2

Figure 2-7: Typical Flooded Loop System

INSTALLATION CHECKLIST

1. All burners are carefully assembled and tested at the factory, but before being placed in service all connectors should again be checked for looseness caused during shipment.

Check:

a. Electrical terminals in the control panel and on all

electrical components. b. Pipe fittings and unions. c. Tubing connections. d. Nuts, bolts, screws.

2. Open all necessary oil shutoff valves. Do not run pumps or fuel unit without oil.

3. Before connecting electrical current to any component, be sure the voltage is the same as that specified on component nameplates.

4. Before burner operation, be sure all motors are rotating in the proper direction.

5. Before firing, make sure the burner firing head and dry areas of the boiler are protected with refractory. The burner mounting flange must be properly sealed against the vessel front plate.

CAUTION

DANGER

BEFORE OPENING THE MANUAL GAS SHUTOFF VALVES, READ THE REGULATOR INSTRUCTIONS CAREFULL Y. THE INSTRUCTIONS ARE IN THE REGULATOR BOX. FOLLOW THE MANUFACTURER RECOMMENDATIONS. OPEN SHUTOFF VALVE ON THE INLET SIDE OF THE REGULATOR SLOWLY AND CAREFULLY TO ALLOW INLET PRESSURE TO BUILD UP SLOWL Y IN THE REGULATOR UNTIL IT IS FULL Y PRESSURIZED. OPEJNING THE SHUTOFF VALVE QUICKLY WILL DAMAGE THE REGULATOR. DO NOT EXCEED THE REGULATOR PRESSURE RA TINGS.

6. Make certain that the operator in charge is properly instructed in operation and maintenance procedures.

750-177 2-11

Chapter 2 Profire V Burner

FIRING MODES

Different modulation modes are available with the Profire V burner. The Model FLX will utilize one of the following:

Low - High -Low (60% damper purge).

Low - High -Low (open damper purge).

Full Modulation (open damper purge).

See following pages for operating descriptions of each firing mode

2-12 750-177

Profire V Burner Chapter 2

LOW-HIGH-LOW MOD - LOW or 60% DAMPER PURGE

Combustion Air Gas Oil

A two blade damper is

COMPONENTS DESCRIPTION:

controlled by a two position, spring return actuator with mechanical linkage. For 60% damper purge a mechanical stop is provided on the damper to ensure sufficient air flow is provided during prepurge. Power to drive the actuator is routed through a low/auto switch and a remote located modulating control. The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system. (see oil at right).

Safety shut off valve(s) are provided to initiate the flow of gas. The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an "in rush" of gas. A butterfly type gas metering valve is linked directly to the damper actuator and provides gas flow metering during the drive to the high position. A manually adjusted gas regulator limits maximum firing rate.

Pressure Atomization: Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle. The oil pump has a built in solenoid controlled two level pressure regulating system. Low and high flow rates are set on the pump based on pressure and the nozzle's flow rating.

PRE-PURGE:

STARTUP, IGNITION:

RUN, MODULATE:

Operating Sequence

SHUT DOWN, POST-PURGE:

Damper is in its closed or low fire position. For 60% damper purge this would be against the mechanical stop.

Damper remains in its low fire starting position.

Damper is driven open in 30 seconds by the two position actuator. Low-High-Low burners will modulate from the low to high rate positions based on the signal from the modulating control and the selection of the low/auto switch.

Damper returns to its start position based on the 25 second closure speed of the mechanical actuator.

Valves are closed.

Valves open. To prevent a surge the primary gas valve opens at a slowed rate. Gas flow to the manifold is metered based on the butterfly valves low fire setting.

The gas valves remain in their open position. The actuator begins it's travel to the high fire position opening the gas metering valve. The burner will then modulate from low to high as described in the combustion air column.

On shut down all gas valves close within 1 second. The butterfly valve closes in 25 seconds with the two position actuator.

The pump is operational but the valves are closed. Oil is flowing through an internal relief valve and returning to the supply system.

Safety shut off valves open allowing oil to flow from pump to nozzle. Oil pressure at the nozzle is based on the pump's low pressure setting. Excess oil is flowing through an internal relief valve and returning to the supply system.

The safety shut-off oil valves remain open. The pump's solenoid is energized by the auxiliary switch within the damper actuator as it opens the air damper. Oil pressure is then increased based the pumps high pressure setting. The burner will then modulate from low to high as described in the combustion air column.

All valves immediately return to their startup or de-energized position. The oil pump is operating with post-purge, but oil is flowing through an internal relief valve and returning to the supply system.

For pumps without the internal dual pressure solenoid an external pressure relief valve and normally open solenoid valve are used.

VARIATIONS: None None

750-177 2-13

Chapter 2 Profire V Burner

LOW-HIGH-LOW MOD - OPEN DAMPER PURGE

Combustion Air Gas Oil

Pressure Atomization: Two solenoid type safety

shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle. The oil pump has a built in solenoid controlled two level pressure regulating system. Low and high flow rates are set on the pump based on pressure and the nozzle's flow rating.

The pump is operational but the valves are closed. Oil is flowing through an internal relief valve and returning to the supply system.

The safety shut-off oil valves remain open. The pump's solenoid is energized by the aux switch within the damper actuator as it opens the air damper. Oil pressure is then increased based the pump’s high pressure setting. The actuator begins its travel to the high fire position opening the gas metering valve. The burner will modulate from low to high as described in the combustion air column.

All valves immediately return to their startup or deenergized position. The oil pump is operating with post-purge, but oil is flowing through an internal relief valve and returning to the supply system.

For pumps without the internal dual pressure solenoid an external pressure relief valve and normally open solenoid valve are used.

COMPONENTS DESCRIPTION

PRE-PURGE

STARTUP, IGNITION

RUN, MODULATE

Operating Sequence

SHUT DOWN, POST-PURGE

A two blade damper is controlled by a two position, spring return actuator with mechanical linkage. Power to drive the actuator is routed through a low/auto switch and a remote located modulating control. The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system. (see oil at right) A second external switch ensures the damper has returned to the low fire position before ignition is initiated.

From its closed position the damper is driven open by the flame safeguard control where it remains for the duration of the pre-purge cycle.

Damper returns to the low fire position which is proven through the external switch. The burner is now ready for startup.

Damper is driven open in 30 seconds by the two position actuator. Low-High-Low burners will modulate from low to high rate positions based on the signal from the modulating control and the selection of the low/auto switch.

Damper returns to its start position based on the 25 second closure speed of the mechanical actuator.

Valves are closed.

Valves open. To prevent a surge the primary gas valve opens at a slowed rate. Gas flow to the manifold is metered based on the butterfly valves low fire setting.

The gas valves remain in their open position. The actuator begins its travel to the high fire position opening the gas metering valve. The burner will modulate from low to high as described in the combustion air column. On shut down all gas valves close within 1 second. The butterfly valve closes in 25 seconds with the two position actuator.

VARIATIONS None None

2-14 750-177

Profire V Burner Chapter 2

FULL MODULATION - OPEN DAMPER PURGE

Combustion Air Gas Oil

A two blade damper is controlled by a proportional modulating actuator (or

COMPONENTS DESCRIPTION

PRE-PURGE

STARTUP, IGNITION

RUN, MODULATE

Operating Sequence

SHUT DOWN, POST-PURGE

VARIATIONS:

motor) with mechanical linkage. The modulating actuator is capable of stopping at any point along its 90 degree stroke based on a signal from a remotely connected modulating control or from a burner mounted manual potentiometer which is selected through an auto/manual modulation selector switch. The actuator also contains two internal switches that ensure the damper reach the high fire and low fire positions during purge and before ignition is initiated.

From its closed position the damper is driven open by a signal from the flame safeguard control where the high fire air switch is proven. The damper will remain open for the duration of the pre-purge cycle.

Damper returns to the low fire position which is proven through the internal low fire air proving switch. The burner is now ready for startup.

Damper is driven by the modulating actuator to a firing rate position as determined by the modulating control or manual potentiometer. Actuator can complete full travel to high fire in 30 seconds. Actuator will then continue to adjust firing rate position based on signals from the modulating control until demand is satisfied.

Damper returns to its starting position based on the 30 second closure speed of the mechanical actuator during post purge.

Options are available for 4-20amp modulating signal conversion or 4-20 proportional modulating actuators. Also optional is an actuator with dual low fire start switch positions for improved "turn down" in dual fuel situations.

Safety shut off valve(s) are provided to initiate the flow of gas. The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an "in rush" of gas. A butterfly type gas metering valve is linked directly to the damper actuator and provides gas flow metering relative to the actuators position . A manually adjusted gas regulator limits maximum firing rate.

Valves are closed.

Valves open. To prevent a surge the primary gas valve opens at a slowed rate. Gas flow to the manifold is metered based on the butterfly valve low fire setting.

The gas valves remain in their open position. As the actuator begins it's travel to the firing rate position it is also adjusting the butterfly gas metering valve increasing the flow of gas to the manifold. The burner will continue to modulate as described under the combustion air heading until demand is satisfied.

On shut down all gas valves close within 1 second. The butterfly valve closes in 30 seconds with the damper actuator.

None

Pressure Atomization: Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to a return flow nozzle. In the return line from the nozzle an adjustable oil metering valve limits the amount of oil allowed to return to the pump. The metering valve is connected to the damper actuator with mechanical linkage.

The pump is operational but the valves are closed. Oil is flowing through an internal relief valve and returning to the supply system.

Safety shut off valves open allowing oil to flow from pump to nozzle. Oil pressure at the nozzle is based on the pump's pressure setting less the volume of oil returning through the metering valve.

The safety shut-off oil valves remain open. As the actuator begins it's travel to the firing rate position it is also adjusting the oil metering valve decreasing the amount of oil allowed to return to the pump. This in turn is increasing the pressure and volume of oil at the nozzle. The burner will continue to modulate as described under the combustion air heading until demand is satisfied.

All valves immediately close. The metering valve opens to it's low fire position in 30 seconds with the damper actuator. The oil pump is operating with postpurge, but oil is flowing through an internal relief valve and returning to the supply system.

On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut-off valve.

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Chapter 2 Profire V Burner

PARALLEL POSITIONING

Combustion Air Gas Oil

COMPONENTS DESCRIPTION

NOTE: Parallel Positioning systems

incorporate independent actuators to control each of the fuel and air metering devices. Customizable "curves" can then be created for each actuator to optimize burner performanc e.

A two bladed damper is controlled by an independent parallel positioning actuator. The remote mounted modulating control

Safety shut off valve(s) are provided to initiate the flow of gas. The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an "in rush" of gas. A butterfly type gas metering valve is directly coupled to a parallel positioning actuator. A manually adjusted gas regulator limits maximum firing rate.

Pressure Atomization: Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to a retu rn flow nozzle. In the return line from the nozzle is an adjustable oil metering valve which limits the amount of oil allowed to return to the pump. The metering valve is direct coupled to a parallel positioning actuator.

PRE-PURGE

STARTUP, IGNITION

RUN, MODULATE

Operating Sequence

SHUT DOWN, POST-PURGE

From its closed position the damper is driven open by a signal from the parallel positioning control. The damper will remain open for the duration of the prepurge cycle.

Damper returns to the low fire position in preparation for startup.

Damper is driven by its parallel positioning actuator to a firing rate position as determined by the parallel positioning control. The actuator and parallel positioning control will then continue to adjust the damper and fuel actuators position based on signals from remote sensors until demand is satisfied.

Damper returns to its closed position during or following post pu rge.

Valves are closed.

Valves open. To prevent a surge the primary gas valve opens at a slowed rate. Gas flow to the manifold is metered based on the butterfly valves low fire setting.

The gas valves remain in their open position. The metering valve and actuator increases the flow of gas to the manifold in conjunction with the opening damper however, position adjustments are made based on the fuel "curve" stored in the parallel positioning control's memory. The burner will continue to modulate as described under the combustion air heading until demand is satisfied.

On shut down all gas valves close within 1 second. The butterfly valve returns to it's starting position..

The pump is operational but the valves are closed. Oil is flowing through an internal relief valve and returning to the supply system.

Safety shut off valves open allowing oil to flow from pump to nozzle. Oil pressure at the nozzle is based on the pump's pressure setting less the volume of oil returning through the metering valve.

The safety shut-off oil valves remain open. The metering valve and actuator decreases the flow of oil returning to the pump in conjunction with the opening damper however, position adjustments are made based on the fuel "curve" stored in the parallel positioning control's memory. This in turn is increases the pressure and volume of oil at the nozzle. The burner will continue to modulate as described under the combustion air heading until demand is satisfied.

All valves immediately close. The metering valve opens to it's low fire position. The oil pump is operating with post-purge, but oil is flowing through an internal relief valve and returning to the supply system.

On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut-off valve.

Several parallel positioning

VARIATIONS

systems available. Consult the factory for types and options.

2-16 750-177

None

Profire V Burner Chapter 2

C. Startup and Operation

When the installation is complete and all electrical, fuel, water, and vent stack connections are made, make certain the connections are tight. The operator should become familiar with the burner, boiler controls and components. To identify controls and components, refer to drawings and contents of Section 1. Adjustment procedures given in Section 4 should be reviewed prior to firing. The wiring diagram should also be studied along with the operating sequence of the burner programmer. Check the electrical power supply for accordance with the nameplate specifications for all motors and controls.

Read and understand starting instructions before attempting to operate the burner. The following checks must be made:

BOILER

Check boiler water level. Be sure all boiler valves are installed correctly and positioned properly. Set the high limit control slightly above the operating control. Set operating control at the desired temperature or pressure.

BURNER

For protection in shipment, the flame safeguard control chassis is shipped unmounted. Check all screw connections before attaching flame safeguard chassis to base. The screw must be secure to assure low resistance connections. The relay chassis is mounted on the subbase with a screw which, when tightened, completes the connection between the subbase and chassis contacts. Press manual reset button to be sure safety switch contacts are closed.

Check fuses in main panel and in the burner control cabinet. Check wiring to the burner control cabinet for compliance with the wiring diagram and local codes. The control cabinet components are 120 volt. If a control transformer is supplied, ensure that the supply voltage matches its primary voltage.

Check motor rotation by momentarily closing the starter or relay. Blower rotation is clockwise when viewed from the drive end.

Check the pilot electrode setting. Refer to the Adjustment section.

Check control linkage for proper movement of the air volume damper and fuel metering components. This can be done by loosening the linkage at the actuator lever and manipulating by hand.

Check the air shutter and adjust low-fire setting. Refer to the Adjustment setting.

FIRING PREPARATIONS

Check to make certain that all plugs, connections. linkages, etc., are tight. Prior to initial firing, oil flow and pressure should be verified.

GAS BURNERS

A representative of the gas utility should turn on the gas. Determine by a test gauge upstream of the burner regulator that sufficient pressure exists at the entrance to the gas train. The gas pressure regulator must be adjusted to the pressure required and the pressure setting recorded.

On combination fuel models, set the selector switch to gas. On initial startup it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through pre-purge and pilot sequences to determine that the main gas valve opens. Turn the burner switch OFF and let the programmer finish its cycle. Check to see that the gas valve closes tightly.

On burners equipped with high and low gas pressure switches, set switch pressure actuating levels and record settings for future service reference.

See the burner specification nameplate inside the control panel door for minimum and maximum input rate and required manifold pressure.

When the conditions covered above and in Section 2 are assured, the burner is ready for firing. Refer to Section E for starting and operating information.

OIL BURNERS

Prior to initial firing, oil flow and pressure should be verified. If the burner is a dual fuel model, make certain that the main gas shutoff cock is closed and the fuel selector switch is set to OIL.

OIL FLOW

If the oil supply tank is below the level of the oil fuel unit, it is recommended that the suction line be primed with oil prior to starting the pump to avoid the possibility of damage to the pump through operation without lubrication.

To check for proper pump rotation, momentarily energize the starter. With rotation verified, operate the pump to determine that oil circulation exists. Observe the oil burner pressure gauge. If not pressure shows after a few moments, stop the oil pump and re-prime. If the supply tank is lower than the pump, it is possible that the initial priming of the suction line, followed by operation of the pump, will not establish oil flow. This might be caused by obstruction in the suction line, excessive lift, inadequate priming, suction line leaks, etc. Until oil flow is established, avoid prolonged operation of the pump. If oil flow is not established after a second priming, investigation is required.

A vacuum (or compound pressure-vacuum) gauge should be installed at the suction port of the pump. It is advisable that the reading be less than 15” Hg vacuum. Vacuum in excess of this may cause unstable firing.

750-177 2-17

Chapter 2 Profire V Burner

OIL PRESSURE AND VACUUM

If the vacuum gauge reads higher than calculated, look for restriction in the suction line, a closed valved, kinked copper tubing, plugged filter, sticking check valve, frozen oil line, undersized oil line, or excessive lift.

When there is a positive head of oil at the fuel unit, either from a gravity or by pump circulation, the pressure must not exceed 3 psi at the fuel unit suction inlet. Special pressure regulating valves are available for suction pressure above 3 psi. The fuel unit discharge pressure should be set at 300 psi.

BURNER SETTINGS

To ensure reliable and safe burner performance, the location and gap setting of the electrode for direct spark igniters, and the relative positions of the burner nozzle, diffuser, and air baffle components must be correctly set. The air damper blades must be adjusted, relative to the established flow rates to provide the correct amount of air for complete efficient combustion.

These items are preset at the factory, but must be checked prior to placing the burner into initial service, or after conducting any service work that may have altered their position.

Refer to Section 4, ADJUSTMENTS, for the instructions.

COMBUSTION SETTINGS

Fuel and air flow rates are individually adjusted at low-fire and at high-fire to achieve rated heat input, firing rate turndown, optimum efficiency, safe operation, and the ability to cope with environmental changes (including air temperature, humidity, barometric pressure), and fuel property changes. Refer to the nameplate inside the control panel for minimum and maximum fuel input ratings.

Refer to Section 4, ADJUSTMENTS, for the instructions.

TEST EQUIPMENT

The following test equipment should be on site:

6. Stack Thermometer and Thermocouples.

WARNING

DANGER

CAUTION

DANGER

TO PREVENT POSSIBLE SERIOUS INJURY OR DEATH, READ THE FLAME SAFEGUARD MANUAL AND FULLY UNDERSTAND ITS CONTENT BEFORE ATTEMPTING TO OPERATE THIS EQUIPMENT.

WARNING

DANGER

CAUTION

DANGER

SHOULD A STARTING FAILURE OCCUR FOR ANY REASON, COMBUSTIBLE FUMES MAY FILL THE COMBUSTION CHAMBER. NEVER ATTEMPT TO RE-LIGHT THE BURNER UNDER THESE CONDITIONS WITHOUT PURGING THE CHAMBER.

SEQUENCE OF OPERATION

The programming control sequences the operation of all controls and components through the starting, ignition, firing, and shutdown cycle. The burner and control system are in starting condition when:

• The operating and high limit control (temperature or pressure) are below their cutoff setting.

• All power supply switches are closed.

• Power is present at the control panel.

Refer to the manufacturer’s literature on programming controls and burner wiring diagrams for detailed information.

1. Combustion analyzer with O2 indication.

2. U-Tube manometer, or pressure gauge, to measure gas pressures (main and pilot), pressures and vacuum gauge for the oil burners.

3. Inclined manometer to measure draft pressures.

4. Smoke spot tester for oil burners and CO analyzer for gas fired units.

5. Voltmeter/Ammeter.

2-18 750-177

ELECTRICAL INTERFACE TEST

Prior to putting the burner into service, conduct the following test to ascertain that ignition spark will not cause the flame relay to pull in.

GAS FIRED

Close the pilot and main line manual gas valves. Start the burner and at time of pilot trial with just the electrical ignition system energized. The flame relay should not pull in (should not be energized).

Upon completion of successful test, proceed with startup procedures.

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