CleaverBrooks FLX-400, FLX-450, FLX-500, FLX-600, FLX-550 Operation, Service And Parts Manual

...

MODEL

PACKAGED BOILER

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

Hot Water and Steam

Fuel: Light Oil, Gas or Combination

FLX

Manual Part No. 750-177 R6

5/2014

MODEL FLX

PACKAGED BOILER

Operation, Service, and Parts Manual

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

Fuel: Light Oil, Gas or Combination

 Cleaver-Brooks 2014

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

Manual Part No. 750-177 R6 Revised 5/2014

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 OPERA TE, SERVICE, OR REP AIR THIS EQUIPMENT UNLESS THEY FULL Y 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 fol lowed. 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 oper ating 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, main tain, 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-con necting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel is of extreme importance. W aterside 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

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

B. Firing Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

C. Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

D. Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

E. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

F. Startup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

G. Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

H. Gas System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34

I. Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37

J. Combination Gas-Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

K. Modulation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40

L. Air and Fuel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

M. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43

N. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

O. Burner Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Chapter 3

Pressure Vessel Care

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

B. Water Requirements (Hot Water Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

C. Water Requirements (Steam Boilers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

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

E. Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

G. Boilout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

H. Washing Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

I. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

J. Preparation For Extended Layup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Chapter 4

Sequence Of Operation

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

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

C. Sequence Of Operation - Oil Or Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

Chapter 5

Adjustment Procedures

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

B. Linkage - Modulating Motor & Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

J. Operating Limit Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

K. High Limit Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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

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

N. Gas Pilot Flame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

O. Gas Pressure and Flow Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

P. Gas Fuel Combustion Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Q. Low Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

R. High Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

S. Fuel Oil Pressure and Temperature - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

T. Fuel Oil Combustion Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

U. Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Chapter 6

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

iii

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

Parts

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

Safety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13

CHAPTER 1

DANGER

CAUTION

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.

Figure 1-1: FLX cutaway view

General Description

D. Steam Controls (All Fuels) 1-2

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

A. General

This manual covers Cleaver-Brooks Model FLX boilers in sizes ranging from 1,500,000 to 12,000,000 Btu/hr input.

Fuel Series

700 - Gas 100 - No.2 0il 200 - Combination Gas & No.2 Oil

A. General 1-1

B. The Boiler 1-2

C. Construction 1-2

Design Pressure

160 psig hot water 15 psig steam 150 psig steam

750-177 1-1

Chapter 1 General Description

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

DANGER

CAUTION

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.

The boiler and related equipment installation are to be in compliance with the standards of 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 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 National Board

Steam

Steam boilers are designed for low and high pressure applications. 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.

Low pressure boilers are limited to 15 psig

ABC

EFG

Hot Water

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 and hot water boilers are defined according to design pressure and operating pressure. Des

ign 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.

The type of service that your boiler is required to provide has an

important bearing on the amount of waterside

care it will require.

Waterside care is of prime importance. For specific information or assistance with your water treatment requirements, contact your Cleaver- Brooks service and parts representa tive. Failure t o follow

hese instructions could result in equipment damage.

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

The careful observance of water requirements for both stea

m and hot water boilers is essential. 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 pressur

e 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 this chapter before attempting to place the unit into operation.

1-2 750-177

General Description Chapter 1

Figure 2-2: Steam Controls

4,5

DANGER

CAUTION

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. High Limit Pressure Control: 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.

2. Operating Limit Pressure Control: Breaks a circuit to stop burner operation on at a selected setting. It is adjusted to stop or start the burner at a preselected pressure setting.

3. Modulating Limit Pressure Control: Senses changing b information to the modulating motor to change the burner firing rate when the manual-automatic switch is set on “automatic.”

oiler pressures and transmits the

a rise of boiler pressure

4. Low Water Cutoff and Pump Control: Floatoperated control boiler. It performs two distinct functions:

• Stops firing of the burner if water level lowers

low the safe operating point. Energizes the low-

be 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.

Determine that the main and auxiliary low water cutof fs and pump control are level a fter installation and throughout the equipment’s operating life. Failure to follow these instructions could result in equipment damage.

5. Water Column Assembly: Houses the low-water cutoff and pump control and includes the water gauge glass and

6. Water Column Drain Valve: Provided so that the water column and

7. Gauge Glass Drain Valve: Provide

gauge glass shutoff cocks.

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.

responds to the water level in the

its piping can be flushed regularly to assist in

d to flush the gauge glass.

750-177 1-3

Chapter 1 General Description

DISCHARGE OPENING MUST BE EQUAL TO OR LARGER THAN INLET

CAUTION VENT PIPE MUST NOT TOUCH DRIP PAN EXTENSION

SUPPORT FROM BUILDING

CONSTRUCTION

VENT

DRIP PAN

EXTENSION

DRIP PAN

AND ELBOW

DRIP PAN

DRAIN

VENT PIPE

OPEN DRAIN

TO WASTE

BOILER SHELL

SAFETY VALVE

DRIP ELL DRAIN

WATER L EVE L

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

TO STEAM

1 1/2”

MIN.

Figure 2-3: Recommended piping for steam relief

valve (not furnished by Cleaver-Brooks)

DANGER

WARNING

Figure 2-4: Hot Water Controls

8. Safety Valve(s): 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 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 draw the mounting bolts down evenly. Do not install or remove side outlet valves by using a pipe or wrench in the outlet.

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)

1. Water Temperature Gauge: Indicates the boiler internal water pressure.

2. Water Pressure Gauge: Indicates the internal pressure of the

3. High Limit Temperature Control: Breaks a circuit to stop bu selected setting. It is adjusted to stop burner at a preselected temperature above the operating control setting. The high limit temperature control is

rner operation on a rise of temperature at a

equipped with a manual reset.

4. Operating Limit Temperature Control: Breaks a

cuit to stop burner operation on a rise of boiler

cir temperature at a selected setting. It is adjusted to stop or start the burner at a preselected operating temperature.

5. Modulating Temperature Control: 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: Breaks the circuit to s point, activating low-water light and optional alarm bell if burner is so equipped.

boiler.

top burner operation if the water level in the boiler drops below safe operating

1-4 750-177

General Description Chapter 1

DANGER

WARNING

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.

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.

750-177 1-5

Chapter 1 General Description

1-6 750-177

A. Introduction

DANGER

CAUTION

CHAPTER 2

Profire V Burner

A. Introduction 2-1

B. Firing Head 2-4

C. Oil System 2-4

D. Gas System 2-7

E. Installation 2-9

F. Startup and Operation 2-19

G. Adjustments 2-26

H. Gas System 2-34

I. Oil System 2-37

J. Combination Gas-Oil System 2-39

K. Modulation Control 2-40

L. Air and Fuel Controls 2-42

M. Maintenance 2-43

N. Troubleshooting 2-50

O. Burner Specs 2-53

V series burners are assembled, wired, and tested at the factory. They are listed by the Underwriters Laboratory (UL), CSD-1, NFPA-85, Factory Mutual (FM), including the National Electrical Code (NEC), and associated insurance underwriters. Where applicable, the Canadian Gas Association (CGA) B149 and the Canadian Standards Association (CSA) B140 codes shall prevail. Other regulatory agency control options are available.

ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST, OR SER

DESCRIPTION

The V series burners are designed to operate with natural gas and automatic, unattended operation except for periodic inspection and maintenance. The burner and control panel components require little attention except for occasional cleaning.

Model FLX boilers 150-1200 MBTU use the following size burners:

SIZE 1 - FLX 150-300 (Low-High-Low or Full Modulation) SIZE 2 - FLX 350-550 (Low-High-Low or Full Modulation) SIZE 3 - FLX 600 (Low-High-Low SIZE 3 & 4 - FLX 700-1200 (Full Modulation)

VICE THIS EQUIPMENT.

light oil. The burners are designed for

or Full Modulation)

750-177 2-1

2-1

Chapter 2 Profire V Burner

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.

The following table lists typical panel items. Some or all of the items may be provided depending on the burner configuration selected.

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.

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 (full modulation burners only) increases or decreases the burner

firing rate.

6. SIGNAL LAMPS

a) LOAD DEMAND (white): Illuminates when the control circuit is energized (powered).

b) LOW WATER (red): Illuminates when the water level in the boiler gets too low.

c) FUEL VALVE (green): Illuminates when the main fuel valve or valves (gas or oil) are energized (open).

d) FLAME FAILURE (red): Illuminates when the flame safeguard system fails to detect pilot or main flame.

ABC

EFG

FLAME SAFEGUARD CONTROLS

The flame safeguard controls the burner's operating sequence: pre-purge, trial for ignition, main flame and

shutdown. This safety control also includes flame detection system to confirm proper operation or cause a manual reset lockout in the event of a pilot or main flame failure. External controls connected to the flame control's limit circuit, such as the boiler operating control, will trigger normal burner startup, and upon reaching operating set point, normal burner shutdown. Safety devices in the flame control's running interlock circuit, such as the combustion air switch, will cause an immediate safety shut down if conditions are not correct for safe operation.

When a parallel positioning system is furnished, the flame safeguard may be incorporated as an integral component to the parallel positioning control. Consult boiler controls documentation. If using a C-B Hawk control system refer to manual 750-366 (Hawk 1000) or 750-342 (Hawk 4000) and to the flame safeguard manual 750-234 (CB780E) or 750-264 (CB120).

FIRING RATE CONTROLS

LHL burners use a two position actuator and linkage to control the air and gaseous fuels (oil burners control oil flow with electric valves). At startup fire, the air damper and fuel valves are positioned for stable low fire operation. When the actuator is commanded to its second position, the linkage drives the air damper and fuel val ves o p e n u nti l h igh f ire is reached. LHL burners typically use a boiler-mounted control that keeps the burner at its low fire rate to prevent thermal shock, until conditions are suitable for high fire.

Full modulation burners are capable of firing at any rate between the burner's low and high fire limits. For “single point” modulating systems, a single rotary actuator controls both air and fuel volume via control arms and linkage attached to its shaft. As the actuator rotates from low to high fire, the linkage opens the air damper

2-2 750-177

Profire V Burner Chapter 2

and fuel metering valves increase the firing rate. Optional “CAM” trim provides additional precision to the air/ fuel mix with the use of several discrete set point adjustments across the modulation range. Further combustion efficiency may be achieved with the use of parallel positioning controls which use multiple directly-coupled actuators (linkeageless) to position the air damper, fuel metering valves and, if applicable, flue gas recirculation (FGR) across the modulation range.

COMBUSTION AIR HANDLING SYSTEM

1. MOTOR AND BLOWER

The impeller is directly driven by the motor at 3450 rpm.

2. AIR VOLUME REGULATOR

Air dampers are located in the air inlet housing and 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

Contained by the burner’s firing head, an air flow diffuser shapes combustion air flow and improves flame stability.

When determining boiler room air requirements, the size of

the room, air flow, and velocity of air must be

reviewed as follows (fpm = feet per minute; cfm = cubic feet per minute):

Two (2) permanent air supply openings in the outer walls of the boi ommended. Locate one (1) at each end of the boiler room, preferably 7 foot or lower. This allows air to sweep the length of the boiler.

A boiler room vent fan is not recommended. Under cer can cause a light vacuum and “steal” combustion air from the burner resulting in

Size (area) and location of air supply openings in boiler room:

Amount of air required (cfm): Combustion Air = Rated bhp x 8 cfm/bhp.

Acceptable air velocity in Boiler Room (fpm):

unsatisfactory combustion performance.

A vent fan in the boiler room is not recommended, as it could create a light vacuum under certain conditions and cause variations in the volume of combustion air. This can result in unsatisfactory burner performance.

Under no condition should the total (1)square foot.

Size the openings by using the formula:

Ventilation Air = Maximum bhp x 2 cfm/bhp.

Total recommended air = 10 cfm/bhp – up to 1000 feet elevation. Add 3% more per 100

From floor to (7) foot height – 250 fpm

Above (7) foot height – 500 fpm

0 feet of added elevation.

area of the air supply openings be less than

Area (sq-ft) = cfm/fpm

ler room are rec-

tain conditions, these fans

Example: Determine the area of the boiler room air supply openings for one (1) 300 hp boiler at 800 feet altitude. The air openings are to be 5 feet above floor level.

1.Air required: 300 x 10 = 3000 cfm

2.Air velocity: Up to 7 feet - 250 fpm

3.Area required: Area = cfm = 3000/250 = 12 sq-ft total

4.Area/Opening: 12/2 = 6 sq-f

750-177 2-3

t/opening (2 required)

Chapter 2 Profire V Burner

RADIAL GAS SPUDS

CHOKE RING

MOUNTING FLANGE

AIR BAFFLE

GAS MANIFOLD

NOZZLE BODY

AND TIP

DIFFUSER

B. FIRING HEAD

Two side access covers provide access to the firing head internal components. Figure 2-1 shows a a radial spud firing head typically used on watertube applications

Figure 2-1: Profire V firing head

C. OIL SYSTEM

The V series burners pump high pressure fuel oil to the spray nozzle resulting in combustion-ready finely atomized oil spray.

Oil System Components

Fuel Unit Standard V13-55 have an oil pump flex-coupled to the blower motor; these units may be

optionally equipped with a remote pump.The larger V60-168 use a remote pump with separate motor.

Oil Nozzle Pump pressurized oil discharges from the nozzle in a fine conical spray pattern. The burner's

nozzle is sized to provide the burner's high fire rate, rated gallons per hour (gph). Smaller gph nozzles may be used to match burner output to a heat exchanger's required input. Models V1334 are supplied with simplex nozzles (return flow nozzles optional on V25-34). Models V35168 are supplied with return flow nozzles.

Nozzle Adapter A nozzle adapter provides the means for connecting fuel lines with the nozzle.

Oil Solenoid Valves Two normally closed (N.C.) and one normally open (N.O

tem on LHO and LHL burners. The two the one N.O. valve cycles the burner to high fire when closed.

Oil Metering Valve The firing rate is controll

metering valve is open, and is closed at high fire.

ed by an adjustable metering valve in the return line. At low fire, the

(2) N.C. valves provide positive shutoff of fuel oil while

Oil Filter The oil filter prevents foreign matter from entering the

as an option and shipped loose with the burner.

.) solenoid valves are part of the oil sys-

burner oil system. This item is provided

2-4 750-177

Profire V Burner Chapter 2

MODULATING

MOTOR

FUEL UNIT

PRESSURE TAP

FUEL UNIT

OIL

METERING

VALVE

OIL

NOZZLE

OIL RETURN

TO TANK

OIL PRESSURE SWITCH

OIL SUPPLY

656-10211-000

OPERATION: Fuel oil is delivered to the fuel pump, either by gravity, fuel pump suction, or by a circulating pump, through a fuel oil filter. Pressurized fuel returns to the storage tank until the two solenoid valves open. Straight oil burners (VL13-55) employ direct spark ignition where the oil is ignited when the oil solenoid valves open and the spray contacts the electrical discharge from the direct spark electrodes.

Gas-oil VLG burners use a proven gas pilot where the oil is ignited when the oil so

lenoid valves open and the

oil spray contacts the established gas pilot flame.

On full modulation units, the modulating actuator varies the oil metering valve

setting. The metering valve located in the return oil loop reduces the firing rate by opening and allowing more oil to return to the supply tank. Conversely, at high fire, the valve is closed, forcing all oil to exit the spray nozzle.

On LHL units, bypass piping routes most

of the oil back to the storage tank while at low fire. At high fire, a

valve blocks the return loop and forces all the oil through the nozzle.

Figure 2-2: Full Modulation Oil System with Integral Pump & Simplex Nozzle (V13-34)

750-177 2-5

FUEL UNIT

OIL RETURN

TO TANK

OIL NOZZLE

OIL

METERING

VALVE

FUEL UNIT PRESSURE TAP

N.C. VALVES

NODULATING

MOTOR

FUEL UNIT

PRESSURE TAP

OIL SUPPLY

656-10211-000

Chapter 2 Profire V Burner

OIL

NOZZLE

OIL PRESSURE SWITCH

N.C. VALVES

FUEL UNIT PRESSURE TAP

MODULATING MOTOR

OIL RETURN TO TANK

OIL

SUPPLY

OIL

METERING

VALVE

REMOTE FUEL UNIT

OIL SUPPLY TO NOZZLE

656-10211-000

Figure 2-3: Full Modulation Oil System with Integral Pump & Return Flow Nozzle (V13-55)

Figure 2-4: Full Modulation Oil System with a Remote Pump (V60-168)

2-6 750-177

Profire V Burner Chapter 2

D. GAS SYSTEM

Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold.Firing rate is determined by the size and number of ports, by manifold pressure, and by combustion zone pressure. The firing rate is regulated by a rotary, butterfly-type throttling valve at the manifold inlet. The valve is actuated by adjustable linkage from the modulating motor. Depending upon specific requirements, one or two gas safety shutoff valves are provided for installation in the gas train upstream of the butterfly valve. Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating sequence.

MAIN GAS TRAIN COMPONENTS

Depending upon the requirements of the regulating authority

, the gas control system and gas train mayconsist of

some, or all, of the following items:

Gas Volume Valve The butterfly type valve is positioned by linkage from the modulating motor and controls the gas flow rate.

Main Gas Valves Electrically operated safety shutoff v

ers include:

• Models V13-25: diaphragm gas valve & sol

• Models V30-50: one (1) motorized gas valve w/proof of closure or two (2) safety shutoff valves

• Models V55-120: one (1) motorized gas valve w/proof of closure and one (1) safety shutoff valve

• Models V126-168: two (2) motorized gas valves (two moto on all models)

Main Gas Regulator Regulates gas train pressure to specified pressure required at the

pressure regulator adjustment.

Main Gas Cocks Used for manual shutoff of the gas su

downstream of the main gas valve(s) provides a means of testing for leakage through the gas valve(s).

High Gas Pressure Switch (Mo

dels V30-168)

Low Gas Pressure Switch (Mo

dels V30-168)

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 the main gas valve(s) to close. This switch requires manual reset after being tripped.

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.

alve(s) that open to admit gas to the burner.lowfire Standard UL burn-

enoid valve

rized gas valves can be optionally provided

burner manifold.Input is set by main gas

pply upstream of the pressure regulator. A second shutoff cock

OPERATION: Metered gas flows through the main gas shutoff cock, through the pressure regulator 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 unles

s 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.

750-177 2-7

Chapter 2 Profire V Burner

Figure 2-5: Typical Gas Train for Full Modulation System (V13-34)

Figure 2-6: Typical Gas Train for LHO/LHL Systems (V35-63) & Full Modulation Systems (V35-168)

2-8 750-177

Profire V Burner Chapter 2

14.18

1.00WITHIN

ELECTRODE END

TUBE END

TIP TO TUBE GAP OF .16"

GAS PILOT

TO GAS PILOT

REGULATOR

PILOT

VALVE

PILOT

SHUTOFF

COCK

GAS FLOW

PILOT TRAIN

DANGER

CAUTION

DANGER

WARNING

PILOT GAS TRAIN COMPONENTS

Models VL 60-168 as well as all VG and VLG models are supp

lied with a gas pilot system. Oil only models VL 13-55

are supplied with direct spark ignition.

Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to the pilot. It closes

after main flame is established.

Gas Pressure Regulator Reduces gas pressure to that required by the pilot.

Gas Pilot Shutoff Cock For manually closing the pilot gas supply.

Figure 2-7: Pilot train / Pilot assembly

E. Installation

DRAFT CONDITIONS

A boiler or other heating vessel fired with a V series burner does not depend 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 maybe 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 the burner operates m

ust be supplied with adequate fresh air for combustion and ventilation purposes. Fresh air supply must meet or exceed all code requirements. Consult with insurance carrier and/or local authorities for specific regulations.

THE BOILER ROOM PRESSURE MUST BE AT LEAST EQUAL TO THE OUTDOOR ATMOSHERIC PRESSURE. WHERE FAN

R EXHAUST AIR FROM THE BOILER

VENTILATION IS USED, AIR MUST BE FORCED INTO THE BOILER ROOM. NEVE ROOM. ADJOINING AREAS HAVING EXHAUST FANS MUST BE POSITIVELY ISOLATED FROM THE BOILER ROOM.

on chimney draft for proper combustion

750-177 2-9

Chapter 2 Profire V Burner

OIL PIPING

The oil only (VL) and gas-oil (VLG) model burners use pressure

atomization. Fuel oil is provided by a burner mounted fuel pump directly coupled to the blower motor via a flexible coupling for models V13-55. A remote pump is used for models V60-168. The suction and return line sizes (two-pipe system) are based on the suction rate of the fuel pump and not the burner firing rate. Pipe size must be selected so that suction vacuum is within suitable limits.

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:

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

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

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

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 sp

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 ever

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

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

y foot of lift.

ze.

ecific “suction capacity” in gph.

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. Figure 2-8 is a typical installation showing separate su

ction lines for each burner with a common return line.

Figure 2-9 shows multiple burners with separate suction li

nes. Figure 2-10 shows multiple burners with oil supplied by a transfer pump. The circulating pump is sized in this case 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.

Figure 2-11 shows an installation using a day tank. A

Figure 2-12 shows a flooded loop system. The circulating pump

pump supplies oil to the day tank.

is sized according to the maximum burner

firing rate for all burner plus a 30% service factor. The burner return lines feed into the common supply line.

Notice: C-B 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

2-10 750-177

Profire V Burner Chapter 2

Figure 2-8: Typical No. 2 Oil Loop Single Burner

Figure 2-9: Multiple Burners with Separate Sucti o n Li n es

750-177 2-11

Chapter 2 Profire V Burner

Figure 2-10: Typical Oil Loop for Multiple Burners with Transfer Pump

Figure 2-11: Typical Installation Using Day Tank

2-12 750-177

Profire V Burner Chapter 2

Figure 2-12: Typical Flooded Loop System

GAS PIPING

Refer to Figures 2-5 through 2-6 for typical gas piping arrangements.

Normally, the control train is ordered to su it a p ar ticular code or insurance regulation, such as UL/cUL, FM, or GAP. 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 re

gulations of the supplying utility. In the absence of other codes, piping should be in accordance with 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. If a pre-piped and wired gas train is ordered, the components upstream of the first safety shutoff valve are shipped loose. These components should also be mounted by the installer.

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.

750-177 2-13

Chapter 2 Profire V Burner

DANGER

CAUTION

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.

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

BEFORE OPENING THE MANUAL GAS SHUTOFF VALVES, READ THE REGULATOR INSTRUCTIONS CAREFULLY. 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 SLOWLY IN THE REGULATOR UNTIL IT IS FULLY PRESSURIZED. OPEJNING THE SHUTOFF VALVE QUICKLY WILL DAM AGE THE REGULATOR. DO NOT EXCEED THE REGULATOR PRESSURE RATINGS.

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.

2-14 750-177

Profire V Burner Chapter 2

LOW-HIGH-LOW MOD - LOW or 60% 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.

COMPONENTS DESCRIPTION:

A two blade damper is 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.

Damper is in its closed or low

PRE-PURGE:

STARTUP, IGNITION:

RUN, MODULATE:

Operating Sequence

SHUT DOWN, POST-PURGE:

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 2-15

Chapter 2 Profire V Burner

LOW-HIGH-LOW MOD - OPEN DAMPER PURGE

Combustion Air Gas Oil

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

COMPONENTS DESCRIPTION

PRE-PURGE

STARTUP, IGNITION

RUN, MODULATE

Operating Sequence

SHUT DOWN, POST-PURGE

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.

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.

VARIATIONS None None

2-16 750-177

Profire V Burner Chapter 2

FULL MODULATION - OPEN DAMPER PURGE

Combustion Air Gas Oil

Pressure Atomization: Two solenoid type safety shut

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

COMPONENTS DESCRIPTION

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

PRE-PURGE

STARTUP, IGNITION

RUN, MODULATE

Operating Sequence

SHUT DOWN, POST-PURGE

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.

VARIATIONS:

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 actuator 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

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.

750-177 2-17

Chapter 2 Profire V Burner

PARALLEL POSITIONING

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 a return 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.

COMPONENTS DESCRIPTION

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.

From its closed position the damper is driven open by a signal from the parallel

PRE-PURGE

STARTUP, IGNITION

RUN, MODULATE

Operating Sequence

SHUT DOWN, POST-PURGE

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 purge.

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.

IC offers several parallel

VARIATIONS

positioning systems. Consult the factory for types and

None

options.

2-18 750-177

+ 106 hidden pages

CleaverBrooks FLX-400, FLX-450, FLX-500, FLX-600, FLX-550 Operation, Service And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual