CleaverBrooks profire q Installation, Operation And Maintanance

Table Of Contents

ProFire Q

Burner

Gas Only

Installation

Operation

Maintenance

Manual Part No. 750-370 01/2016

Q SERIES

Installation, Operation, and Service Manual

Manual Number: 750-00370

Release Date: January 2016

Information to be filled out by owner

Unit Serial Number:

Date of Installation:

Distributor Information

Name:

Address:

Phone Number:

Copyright © 2016 by Cleaver-Brooks

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or

transmitted in any form or by any means without the prior written consent of Industrial Combus-

tion.

Cleaver-Brooks

351 21st Street

Monroe, WI 53566

608-325-3141

cleaverbrooks.com

PREFACE

It is the responsibility of the owner of this equipment to post and maintain a legible copy of this
Installation, Operation and Maintenance manual while this equipment is in service.

Warning and caution references have been made in this manual and should be adhered to for smooth

operation of the burner.

Warning

!

This symbol precedes information which, if disregarded, may result in injury to the user of the burner or to
others.

Caution

!

This symbol precedes information which, if disregarded, may result in damage to the burner.

NOTE: This symbol precedes information which is vital to the operation or maintenance of the burner.

Model designations are based on the type of fuel(s) to be fired and the amount of furnace pressure to be
overcome. Burner size is based on firing rate (rated input in Btu/hr).

Model Standards Fuel-Air Atomization

Q Gas

The equipment must be installed in accordance with applicable local, state, or Provincial Installation

Requirements including the National Electrical Code (NEC) and Associated Insurance Underwriters.

Where applicable, the equipment shall be installed in accordance with the Provincial Installation

Requirements, or in their absence, the Canadian Gas Association (CGA) B149.1 and B149.2 and Canadian
Standard Association (CSA) B140 and B139 (for oil burners) Installation Codes shall prevail. Authorities
having jurisdiction should be consulted before installations are made. Oil and gas burning equipment shall
be connected to flues having sufficient draft at all times to assure safe and proper operation of the burner.

NOTE: The gas train components ship loose, therefore, the bleed valve will need to be installed and adjusted
in the field. Refer to Chapter 4, section 4-2 for adjustment information.

The Q Series burners are designed to burn gas only as defined by ASTM D396-2010 specifications.

Standard Q Series Specifications

Burner
Model

Q6-037 375 9 1/2 1.0 1.5 4 1.5 4.0 1.25 4.0

Q6-055 550 13 1/2 1.0 1.5 4 1.5 4.0 1.50 4.0

Q6-075 750 18 1/2 1.0 1.5 4 1.5 4.0 1.80 4.0

Q6-100 1,000 24 1/2 1.0 1.5 4 1.5 4.0 2.25 4.0

Q6-130 1,250 30 1/2 1.0 1.5 4 1.5 4.0 2.95 4.0

Q6-150 1,500 36 1/2 0.75 1.5 6 2.0 4.0 - 4.0

Q8-175 1,750 42 3/4 1.0 1.5 6 2.0 4.0 3.45 5.75

Q8-200 2,000 48 3/4 1.0 1.5 6 2.0 4.0 3.80 5.75

Q8-250 2,500 60 3/4 0.75 1.5 10 2.0 4.5 - 5.75

Gas
Input
MBtu/hr

BHP
@80%
Eff.

Blower
Motor
HP

Furnace
Pressure
(“w.c.”)

Gas
Train
Size
(in.)

Min. Gas
Pressure
Required
(“w.c)

Low
Pressure
Gas Train
Pipe Size
(in.)

Low Gas
Pressure
Inlet
(“w.c.)

Air Inlet
Orifice
Size (in.)

NOTES:

1. Gas input based on natural gas at 1,000 Btu/cu. ft. and 0.60 gravity.

2. For total pressure at manifold, add furnace pressure.

3. Boiler overall efficiency of 80% estimated.

4. Blower wheel and motor HP is based on altitude up to 2,000 ft. above sea level. For higher altitude or 50 Hz.

applications, consult factory.

5. Firing at higher furnace pressures de-rates the burner by approximately 5% per 1/2” of additional pressure.

Consult factory.s

6. Blower Motor Voltage/ Ph. 60 Hz: 115/1

Fresh
Air Inlet
Size
(in.)

Q Series On-Off Standard Dimensions

12X R

ØN

ØM

P

L

E

D

60°6X

30°

45°

90°4X

ØK

F

J

G

H

Accompanying dimensions are for layout purposes only.

Burner Model

DIM Q6 Q8

Length in inches

Overall burner length H 22 7/8 25 5/8

Width in inches

Center line to left side A 12 1/2 15 5/16

Center line to right side B 5 5/8 6 7/8

Height in inches

Center line to top D 10 11 7/8

Center line to bottom C 4 11/16 4 3/8

Hinge pivot point in inches

Mounting flange to hinge G 22 3/8 25

Hinge swing radius E 17 11/16 20 5/8

Center line to hinge F 4 3/16 3 7/8

Blast tube dimensions in inches

Extension L 2 2

Diameter K 6 8

Mounting flange dimensions in inches

Outer diameter of mounting flange N 12 14

Bolt circle diameter M 7 1/2 9 1/2

Mounting flange slot width R 3/8 1/2

Gas inlet dimensions in inches

Center line to main gas inlet P 5 3/8 6 3/8

Mounting flange to main gas inlet J 2 1/8 2 1/8

C

A B

Q Series Full Modulation Standard Dimensions

12X R

ØN

ØM

E

L

60°6X

30°

45°

90°4X

ØK

F

J

G

H

Accompanying dimensions are for layout purposes only.

Burner Model

DIM Q6 Q8

Length in inches

Overall burner length H 22 7/8 25 5/8

Width in inches

Center line to left side A 12 1/2 15 5/16

Center line to right side B 5 5/8 6 7/8

Height in inches

Center line to top D 10 11 7/8

Center line to bottom C 4 11/16 4 3/8

Hinge pivot point in inches

Mounting flange to hinge G 22 3/8 25

Hinge swing radius E 17 11/16 20 5/8

Center line to hinge F 4 3/16 3 7/8

Blast tube dimensions in inches

Extension L 2 2

Diameter K 6 8

Mounting flange dimensions in inches

Outer diameter of mounting flange N 12 14

Bolt circle diameter M 7 1/2 9 1/2

Mounting flange slot width R 3/8 1/2

Gas inlet dimensions in inches

Center line to main gas inlet P 18 1/2 19 1/2

Mounting flange to main gas inlet J 5 5/8 5 5/8

D

C

A B

P

Q Series Spare Parts List

PART DESCRIPTION - COMMON PARTS BURNER SIZE PART NUMBER

Ignition Transformer Q6 & Q8 832-00954

Light Indicator, White Q6 & Q8 881-00136

Light Indicator, Red Q6 & Q8 881-00137

Light Indicator, Green Q6 & Q8 067-01126-000

Light Indicator, Amber Q6 & Q8 894-04076-000

Air Switch Q6 & Q8 836-01598-000

Electrode Q6 & Q8 435-00585-000

PART DESCRIPTION - BURNER MODEL PARTS BURNER SIZE PART NUMBER

Baffle Weldment Q6 009-04226-000

Baffle Weldment Q8 009-04227-000

Burner Housing Q6 160-00684-000

Burner Housing Q8 160-00727-000

Gasket Q6 853-02408-000

Gasket Q8 853-02409-000

Fan/Blower Unit Q6 894-04076-000

Fan/Blower Unit Q8 894-04111-000

PART DESCRIPTION - CONTROL COMPONENTS BURNER SIZE PART NUMBER

Display, Siemens - Full Mod Siemens Q6 & Q8 833-05071-000

Cable, Display Siemens - Full Mod Siemens Q6 & Q8 826-00315-000

Controller, Siemens - Full Mod Siemens Q6 & Q8 833-09334-000

Controller - Carlin Flamerod Models Q6 & Q8 833-05047-000

Controller - Honeywell Flamerod/UV Models Q6 & Q8 833-01566

Controller - Fireye Flamerod Models Q6 & Q8 833-05401-000

Controller - Fireye UV Scanner Models Q6 & Q8 833-05405-000

Valve, Butterfly - Full Mod Siemens Q6 & Q8 940-01254

Actuator, Fuel Valve - Full Mod Siemens Q6 & Q8 269-00166-000

Coupling - Full Mod Siemens Q6 & Q8 819-00337-000

Flame Rod - All Flame Rod Models Q6 & Q8 067-01126-000

UV Scanner - Full Mod Siemens UV Scanner Q6 & Q8 994-15597-000

UV Scanner - Honeywell UV Scanner Q6 & Q8 798-05109-000

UV Scanner - Fireye UV Scanner Q6 & Q8 817-04696-000

Q Series Spare Parts List Continued

GAS TRAIN

PART DESCRIPTION - GAS TRAIN COMPONENTS

Regulator, Maxitrol RV 1 1/2” All Standard Pressure 817-00622

Valve, Gas Diaphragm 1 1/2” All Standard Pressure 940-01090

Bleed, Used with Gas Diaphragm Standard on All 940-01373

Valve, Gas Solenoid 1 1/2” All Standard Pressure 235-00368-000

Regulator, Air/Gas 1 1/2” Low-High-Low Std. 918-01318-000

Ball Valves 1 1/2” All Standard Pressure 941-00127

Regulator, Maxitrol RV 2” All Low Pressure 817-00617

Valve, Gas Diaphragm 2” All Low Pressure 940-01108

Bleed, Used with Gas Diaphragm Standard on All 940-01373

Valve, Gas Solenoid 2” All Low Pressure 235-00369-000

Regulator, Air/Gas 2” Low-High-Low Pres. 918-01319-000

Ball Valves 2” All Low Pressure 941-00128

Regulator, Maxitrol 210 1” All High Pressure 817-00617

Valve, Gas Diaphragm 1” All High Pressure 940-01103

Bleed, Used with Gas Diaphragm Standard on All 940-01373

Valve, Gas Solenoid 1” All High Pressure 940-01191

Ball Valves 1” All High Pressure 941-00594

Gas Pressure Switch, High Ventless Standard on All 817-00977

Gas Pressure Switch, Low Ventless Standard on All 817-00876

OPTION PART NUMBER

PART DESCRIPTION - ORIFICE BURNER SIZE PART NUMBER

375 MBTU Burner (1.25” diameter) Q6 059-11447-000

550 MBTU Burner (1.5” diameter) Q6 059-11448-000

750 MBTU Burner (1.8” diameter) Q6 059-11449-000

1000 MBTU Burner (2.25” diameter) Q6 059-11450-000

1300 MBTU Burner (2.95” diameter) Q6 059-11452-000

1750 MBTU Burner (3.45” diameter) Q8 059-11457-000

2000 MBTU Burner (3.8” diameter) Q8 059-11458-000

SPRING PIN

ELECTRODE

FIGURE 0-1. Firing Head Assembly w/Flame Rod

ORIFICE PLATE

FLAME ROD

LOCK WASHER

STANDOFF

BAFFLE WELDMENT

LOCK WASHER

SCREW

ELECTRODE

SPRING PIN

NUT

LOCK WASHER

UV SCANNER

SCREW

FIGURE 0-2. Firing Head Assembly w/UV Scanner

ORIFICE PLATE

LOCK WASHER

STANDOFF

BAFFLE WELDMENT

LOCK WASHER

SCREW

Q Series

Table of Contents

CHAPTER 1 Introduction 1-1

1.1 — Overview 1-1

1.2 — Description 1-1

1.3 — Operating Controls 1-2

1.3.1 — Control Panel 1-2

1.3.2 — Flame Safeguard Controls 1-2

1.3.3 — Firing Rate Controls for Modulating Burners 1-2

1.4 — Combustion Air Handling System 1-2

1.5 — Firing Head 1-3

1.6 — Gas System 1-3

1.6.1 — Main Gas Train Components 1-4

1.6.2 — Pilot Gas Train Components 1-5

1.6.3 — Operation 1-5

CHAPTER 2 Installation 2-1

2.1 — Application 2-1

2.2 — Draft Conditions 2-1

2.3 — Combustion Air Supply 2-1

2.4 — Combustion Chamber Recommendations 2-2

2.5 — Installation 2-3

2.5.1 — Support Bracket Installation 2-4

2.6 — Packaging Plastic Refractory Around Oven (If Dry Oven is Supplied) 2-5

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i

2.7 — Gas Piping 2-5

2.8 — Installation Checklist 2-5

CHAPTER 3 Operation 3-1

3.1 — Preparations for Starting 3-1

3.1.1 — Firing Preparations for Gas Burners 3-1

3.1.2 — Burner Settings 3-2

3.1.3 — Combustion Settings 3-2

3.1.4 — Test Equipment 3-3

3.2 — Ignition Adjustment 3-3

3.3 — Startup Sequence 3-3

3.4 — Automatic Shutdown 3-4

3.5 — Manual Shutdown 3-4

3.6 — Safety Shutdown 3-4

3.7 — Startup and Operating 3-5

3.7.1 — Gas Burners (Bubble Test) 3-5

3.7.2 — Burners Designed for On-Off Operation 3-6

3.7.3 — Burners Designed for Low-High-Low Operation 3-6

3.7.4 — Burners Designed for Modulation Operation 3-7

3.9 — Normal Operation 3-9

3.10 — Shutdown 3-10

CHAPTER 4 Adjustments 4-1

4.1 — Overview 4-1

4.2 — Combustion Adjustment on Gas 4-1

4.2.1 — Stack Temperature 4-1

4.2.2 — Gas Adjustments 4-2

4.2.3 — Honeywell V48A Gas Valve Adjustment 4-2

4.3 — Electrical Interference Test 4-2

4.4 — Gas System 4-2

4.4.1 — Gas Pressure 4-2

ii

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ProFire Q Series Manual

4.4.2 — Gas Flow 4-2

4.4.3 — Direct Spark Ignition Flame Adjustment 4-3

4.4.4 — Main Gas Pressure Regulator 4-3

4.4.5 — Low Gas Pressure Switch 4-3

4.4.6 — High Gas Pressure Switch 4-3

4.4.7 — Gas Combustion Adjustment 4-3

4.5 — Parallel Positioning Adjustment 4-4

CHAPTER 5 Maintenance 5-1

5.1 — Overview 5-1

5.2 — Control System 5-1

5.2.1 — Programming Control 5-2

5.3 — Impeller 5-2

5.4 — Firing Head Inspection 5-2

5.5 — Air Filter Inspection 5-2

5.6 — Ignition Electrode & Flame Rod 5-3

5.7 — Flame Scanner 5-3

5.8 — Firing Rate Controls 5-3

5.9 — Burner Mounting Inspection 5-4

5.10 — Gas System 5-4

5.10.1 — Motorized Main Gas Valves 5-4

5.10.2 — Solenoid Valves 5-4

5.11 — Electrical System 5-4

5.11.1 — Electric Motors 5-4

5.12 — Extended Shutdown 5-5

5.13 — Recommended Maintenance Schedule 5-5

750-370
ProFire Q Series Manual

iii

CHAPTER 6 Troubleshooting 6-1

6.1 — Awareness 6-1

6.2 — Emergency Shutdown 6-2

6.3 — Problem/Possible Causes 6-3

STARTUP/SERVICE REPORT

WARRANTY POLICY

iv

750-370

ProFire Q Series Manual

CHAPTER 1 Introduction

1.1 — Overview

Q series burners are completely assembled, wired, and tested at the factory.

Caution

!

Only factory authorized burner service personnel should start up, adjust, or service this equipment.

Warning

!

Burner air, fuel metering valves and positioning motors have not been pre-set by the factory for proper combustion and must
be set by a qualified and authorized technician. Failure to follow this procedure could result in property damage and
personal injury.

The operator must be familiar with the individual functioning of all controls to understand the operations and
procedures described in this manual.

1.2 — Description

The Q series burners are forced draft type burners. All burners feature direct spark ignition. The burner operates with
either on-off, low-high-low, or full modulation. For modulation burners, refer to the LMV37 manual for changing from
automatic fully modulated firing to manually set firing at any desired rate between minimum and maximum. Fully
modulated burners include additional safeguards to assure that the burner always returns to the minimum firing position
for ignition.

Q series burners are designed for automatic, unattended operation except for periodic inspection and maintenance. The
control panel components require little attention except for occasional cleaning.

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1-1

Introduction

1.3 — Operating Controls

1.3.1 — Control Panel

The control panel contains a flame safeguard programming control, load relay, power supply (where applicable), fusing
and terminal strips mounted internally on a panel sub-base. Lights and switches are mounted externally on the panel.
The modulation burner has an external display mounted on the panel.

Component Details

Fusing Control circuit and motor load fusing.

Modulation Display
(Modulation Burner Only)

Signal Lamps

View Window

AZL display is used for commissioning LMV37 control and for automatic or
manual firing rate control, reset lockout and fault history.

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

b) IGNITION (amber): Illuminates when the ignition transformer is powered.

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

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

Window provides visual indication of LED display on the flame safeguard.

1.3.2 — Flame Safeguard Controls

The flame safeguard programmer incorporates a flame sensing cell (scanner) or flame rod to shut down the burner in
the event of ignition 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.

Warning

!

Read the flame safeguard manual and fully understand its contents before attempting to operate this equipment. Failure to
do so may result in serious personal injury or death.

1.3.3 — Firing Rate Controls for Modulating Burners

Burner input is fully modulated between low fire and high fire on boiler demand. The firing rate is controlled by the
linkageless control system. The combustion air flow is controlled by the blower speed. The gas is controlled by a
butterfly valve. The servo rotates 90º from low to high position.

1.4 — Combustion Air Handling System

The combustion air handling system consists of two major components:

Component Details

DC(EC) Motor Full speed modulation with Pulse Width Modulation signal input rated

DC Pulse Width Modulation Blower speed controlled by UGB board for LHL burners or LMV37 (See

1-2

voltage 24VDC, 115VAC

LMV37 manual for details) for modulating burners.

750-370

ProFire Q Series Manual

Introduction

1.5 — Firing Head

Access to the firing head is provided by the side access panel. A flame rod and direct spark is standard on all burners

and a UV scanner is available as an option.

COVER

FLAME ROD

BURNER HOUSING

GAS MANIFOLD

ELECTRODE

BAFFLE PLATE

FIGURE 1-1. Burner Housing

ORIFICE PLATE

750-00509-000

1.6 — Gas System

Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold. The firing
rate is regulated by a main gas regulator and blower inlet choke plate for on-off applications. For full modulation the
fuel metering valve is actuated by the servo. The LMV37 regulates the gas flow in proportion to fan speed which is also
controlled by the LMV37. For low-high-low operation, the gas flow is controlled by the ratio-gas regulator valve. The
ratio regulator regulates the gas flow in proportion to the air pressure. Depending upon specific requirements, safety
shutoff main gas valves are provided for installation in the gas train upstream of the control valves. Safety shutoff gas
valves are wired into the programming control to automatically open and close at the proper time in the operating
sequence.

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ProFire Q Series Manual

1-3

Introduction

1.6.1 — Main Gas Train Components

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:

Component Description

Gas Volume Valve The butterfly-type valve is positioned by the actuator and controls the rate of

flow of the gas.

Main Gas Valves Electrically operated safety shutoff valve(s) that open to admit gas to the

burner. Standard U.L. burners include:

• One solenoid gas valve and one diaphragm gas valve.

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

train. Input is set my the main gas pressure regulator adjustment.

Main Gas Cocks 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).

Ratio-Regulator Valve Controls the rate of flow of gas in proportion to the air pressure

GAS

VALVE

LEAK TEST PORTS

SHUTOFF

VALVE

LEAK
TEST

VALVE

HIGH

GAS

PRESSURE

SWITCH

FIGURE 1-2. Main Gas Train for On-Off Operation (Q6-037 to Q8-250)

VARIABLE

AIR/GAS

RATIO CONTROL

GAS

W/SOLENOID

VALVE

SHUTOFF

VALVE

LEAK
TEST

VALVE

HIGH

PRESSURE

SWITCH

GAS

VALVE

(OPTIONAL

MOTORIZED

FOR

VENTLESS)

GAS

VALVE

LOW

GAS

PRESSURE

SWITCH

LOW

GAS

PRESSURE

SWITCH

REGULATOR

REGULATOR

SHUTOFF

VALVE

750-00515-000

SHUTOFF

VALVE

FIGURE 1-3. Main Gas Train for Low-High-Low (Q6-037 to Q8-250)

1-4

LEAK TEST PORTS

750-00515-000

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ProFire Q Series Manual

Introduction

1

L

U
A

ERFLY

VE

SHUTOFF

VALVE

LEAK
TEST

VALVE

HIGH

GAS

PRESSURE

SWITCH

GAS

VALVE

GAS

VALVE

LOW

GAS

PRESSURE

SWITCH

REGULATOR

SH

V

LEAK TEST PORTS

750-005

FIGURE 1-4. Main Gas Train for Full Modulation (Q6-037 to Q8-250)

NOTE: These piping layouts are for reference only and are subject to change without notice. Optional equipment may change
a layout.

1.6.2 — Direct Spark Components

Component Description

Igniter 14,000 volt single high voltage electrode

1.6.3 — Operation

Metered gas flows through the main gas shutoff cock, through the pressure regulator to the automatic gas valves to the
gas manifold.

For low-high-low burners, the Kromschroeder low/high fire air-gas ratio regulator valve modulates gas flow to the
burner. The air is controlled by a UGB board.

For fully modulating burner, the butterfly gas valve modulates gas flow to the burner. The butterfly valve is positioned
by the servo. The air is controlled by the LMV37 linkageless system.

The automatic gas valve(s) cannot be energized unless the combustion air proving switch is closed and air flow is

detected.

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ProFire Q Series Manual

1-5

Introduction

1-6

750-370

ProFire Q Series Manual

CHAPTER 2 Installation

2.1 — Application

Electrical power and control circuit power is 115 volt, single phase, 60 cycle. Refer to the electrical schematic diagram
shipped with the burner. The schematic is attached to the inside of the control panel cover. Power connections are made
at the control panel. Wiring from the panel to burner mounted components is completed at the factory. Wiring from the
burner panel to boiler controls, low water controls, and remotely located fuel valves is completed by the installer.

2.2 — Draft Conditions

Automatic over-fire draft control or barometric draft regulators are not usually required except where the system has a
tall chimney. The exact height of a chimney requiring draft control is indeterminate, but draft regulation is seldom
needed for chimneys less than 50 feet high, especially with Scotch Marine or sealed firebox boilers. Gas piping
instructions are described in this chapter.

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

Warning

!

The boiler room pressure must be at least equal to the outdoor atmospheric 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.

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2-1

2.4 — Combustion Chamber Recommendations

The combustion chamber dimensions should be adequately sized to prevent flame impingements.

A

B

C

(MIN)

Installation

STANDARD

FIREBRICK

Burner
Size

A

(in.)

B

(in.)

C

(in.)

Combustion

Chamber

Min. Width

(in.)

Combustion

Chamber

Min. Length

(in.)

Q6-037 2 6 10 8 20

Q6-055 2 6 10 8 24

Q6-075 2 6 10 10 24

Q6-100 2 6 10 12 24

Q6-130 2 6 10 12 36

Q6-150 2 6 10 14 36

Q8-175 2 8 12 14 48

Q8-200 2 8 12 16 48

Q8-250 2 8 12 16 48

FLOOR

BLOCK INSULATION

750-00511-000

FIGURE 2-1. Combustion Chamber Dimensions

2-2

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ProFire Q Series Manual

Installation

A

B

Burner Model Boiler HP A (in.) B (in.)

Q6-037 9 8 20

Q6-055 13 8 24

Q6-075 18 10 24

Q6-100 25 12 24

Q6-130 30 12 36

Q6-150 36 14 36

Q8-175 42 14 48

Q8-200 50 16 48

Q8-250 60 16 48

FIGURE 2-2. Burner Model/Boiler HP

2.5 — Installation

750-00512-000

Allow enough clearance at the bottom of the burner to allow the proper air supply. Many boilers, including some Scotch

Marine types, do not have sufficiently rigid front plates and require additional support under the burner base. Boilers
operating with the combustion pressure above atmospheric pressure must be sealed to prevent escape of combustion
products into the boiler room. The burner mounting flange is designed to provide for a seal. The face of the boiler and
burner flange must be sealed with a burner flange gasket (ensure burner flange gasket is installed properly). Make sure
the dry oven and burner blast tube are concentric. For maximum safety, it is recommended that boilers not operating
under pressure should also be sealed.

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ProFire Q Series Manual

2-3

Installation

2.5.1 — Support Bracket Installation

Once the burner is installed, it must be supported from the floor to another suitable weight bearing surface. Provisions
have been made to the burner for the support bracket installation. Kit number 880-06384-000 is supplied with the
burner and includes the support bracket and hardware. A 3/4” NPS pipe must be supplied by others.

SUPPORT BRACKET
(SUPPLIED WITH BURNER)

PIPE, 3/4" NPS (TOE)

(SUPPLIED BY OTHERS)

FIGURE 2-3. Support Bracket Installation

SIZE "A" "B" "C" "D" "E"

66.57.81/4-20

88.59.83/8-16

45°

90°4X

SIZED TO

1.0
FIT BOILER

"A"

750-00520-000

A

"B"

4X "C" X "D" LG
STUDS

4.00

45°

"E"

1.44

A

FIGURE 2-4. Q Series Refractory Dimensions

2-4

SECTION A-A

710-00775-000

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ProFire Q Series Manual

Installation

2.6 — Packing Plastic Refractory Around Oven (If Dry Oven is Supplied)

Caution

!

It is important that you provide support for the housing when in the open position to prevent damage to the burner and sub­sequent components.

The area between the outside circumference of the blast tube and existing refractory should be packed with Kaiser

Refractory Mono T-9 Airset or equal within two hours after coating the dry oven with Trowleze. From inside the fur­nace, ram the plastic refractory from the front to the rear, parallel to the outside surface of the dry oven.

2.7 — Gas Piping

Refer to Figures 1-2,1-3, and 1-4 for typical gas piping schematics.

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. Z 223.1 (for Canada, the Canadian Gas Association (CGA) B149 and
Canadian Standards Association (CSA) B140 codes shall prevail).

On-Off operation gas train components are shipped loose. Full modulation gas train components upstream of the
butterfly valve are shipped loose. These components should be mounted by the installer as close to the burner as
practical. Normally, the control train is ordered to suit a particular code or insurance regulation, such as Underwriters
Laboratories Inc., CGA, or Factory Mutual.

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

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

performed.

2.8 — Installation Checklist

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:

• Electrical terminals in the control panel and on all electrical components.

• Pipe fittings, unions and tube connections.

• Nuts, bolts, screws.

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

Before firing, make sure that the burner mounting flange is properly sealed to the boiler front plate.

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Installation

It is the installers responsibility to identify the main electrical power disconnect and the manual shut-off valve on the
gas supply drop-line to the burner.

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

Caution

!

Before opening the gas shutoff valves, read the regulator instructions carefully. Open the shutoff valve slowly to allow inlet
pressure to build up slowly in the regulator until it is fully pressurized. Opening the shutoff valve quickly will damage the
regulator.

Do not exceed the regulator pressure ratings.

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CHAPTER 3 Operation

3.1 — Preparations for Starting

When the installation is complete and all electrical, fuel, water, and vent stack connections are made, make certain that
all connections are tight. The operator should become familiar with the burner, boiler controls, and components. To
identify controls and components, refer to contents of Chapter 1. Adjustment procedures given in Chapter 4 should be
reviewed prior to firing. The wiring diagram should also be studied along with the operating sequence of burner
programmer. Read and understand starting instructions before attempting to operate the burner. Before attempting to
start the burner, the following checks must be made:

Item Check

Boiler Check the boiler water level. Be sure all boiler valves are installed correctly and

positioned properly. Set the high limit control slightly above the desired
temperature. Set the operating control to the desired temperature or pressure. Set
modulating controls at the desired temperature or pressure.

Burner Check the electrical power supply to the burner in accordance with the nameplate

voltage on all motors and the control circuit.

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

Check the control actuator for proper movement of the fuel metering components.

Adjust low fire and high fire air-gas ratio regulator for low-high-low burners.

Refer to the Siemens LMV37 manual to commission the Siemens LMV37 control
system.

3.1.1 — Firing Preparations for 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.

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On initial startup, it is recommended that the main gas shutoff cock remain closed until the programmer has cycled
through pre-purge and ignition 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. Set the high and low gas pressure
switches.

Check for leaks and determine there is adequate gas pressure available at the burner for operating at full capacity.
Check with the local utility if necessary. Check gas pressure at the main burner. Close the manual gas valve.

3.1.2 — Burner Settings

To ensure reliable and safe burner performance, the fan speed must be adjusted, relative to the established flow rates, to
provide the correct amount of air for complete efficient combustion.

For on-off operation, adjust the main gas regulator to set the correct rate.

For low-high-low operation, separate low fire and high fire adjustments must be made as these are not preset at the
factory. Low and high gas settings are made on the Kromschroeder gas/air ratio regulator valve. Low fire and high fire
fan speeds are adjusted on the UGB board trim potentiometers. Refer to the Kromschroeder and UGB operation manual
for adjustment information. See Section 3.7.3 for valve and UGB adjustment.

For full modulation operation, the fan speed and gas settings are not preset at the factory, and must be checked and
adjusted prior to placing the burner into initial service, or after conducting any service work that may have altered its
settings. The modulating firing rate is controlled by a boiler or vestibule mounted sensor from a temperature or
pressure controller capable of generating a 4-20 mA output signal (minimum 500 ohm impedance). for optimal
efficiency the controller used should be capable of PID load control. The purge rate, ignition position, minimum firing
rate, maximum firing rate and fuel-air ratio throughout the firing range is determined by settings made in the Siemens
LMV37 display. Refer to the Siemens LMV37 operation manual for further information. See Section 3.7.4 for control
adjustment.

See the chart below for the proper air-inlet size:

Burner Model Air-Inlet Size (in.)

Q6-037 1.25

Q6-055 1.50

Q6-075 1.80

Q6-100 2.25

Q6-130 2.95

Q6-150 -

Q8-175 3.45

Q8-200 3.80

Q8-250 -

3.1.3 — 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

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temperature, humidity, barometric pressure), and fuel property changes. Refer to the nameplate inside the control panel
for minimum and maximum fuel input ratings.

3.1.4 — Test Equipment

The following tests should be conducted on site:

1. Combustion analyzer with O

2. U-Tube manometer, or pressure gauge, to measure gas pressures (Main)

3. Inclined manometer to measure draft pressures

4. CO analyzer

5. Voltmeter/Ammeter

6. Stack thermometer and thermocouple

Should a starting failure occur for any reason, combustible fumes may fill the combustion chamber. Never attempt to re­light the burner under these conditions without first purging the chamber.

Read the flame safeguard manual and fully understand its content before attempting to operate this equipment. If this
instruction is ignored, serious injury or death may result.

indication

2

Warning

!

Warning

!

3.2 — Ignition Adjustment

The ignition flame is regulated by adjusting either the main butterfly valve or the ratio regulator. Normal setting is 0.5"
W.C. when the burner is on. The flame must be sufficient to be proven by the flame detector and ignite the main flame.

Although it is possible to visibly adjust the size of the minimum flame, obtain a proper DC volt or microamp reading of

the flame signal. Refer to Flame Safeguard manufacturers instructions for optimal flame signal readings.

Some flame safeguard amplifier or flame safeguard chassis body has a meter jack for this purpose. At initial startup and
during planned maintenance, test the flame signal, burner turndown, and safety switch lockout.

3.3 — Startup Sequence

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.

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Operation

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

1. Begin starting sequence, with burner switch off, and with all manual valves closed. Switch main power on.

2. Open the main manual gas shutoff valve.

3. Manually reset the high and low gas pressure switches.

4. When the burner motor starts, partially open the leak test gas valve.

5. When the main fuel lamp lights indicating ignition flame proven, slowly open the leak test valve downstream of the

main gas valve(s).

Refer to the manufacturer’s literature on primary control sequence of operations.

3.4 — Automatic Shutdown

Limit or operating controls open:

1. Fuel valves close. Main fuel lamp goes off. Flame safeguard timer starts.

2. Flame safeguard timer and burner motor stop. Burner is ready for startup on the next call for heat.

3.5 — Manual Shutdown

When the burner motor stops, close all manual valves.

3.6 — Safety Shutdown

Warning

!

Read the Flame Safeguard manual and fully understand its contents before attempting to operate this equipment. If the
manual is not read and understood, serious personal injury or death may result.

Warning

!

Should a starting failure occur for any reason, combustible fumes may fill the combustion chamber. Never attempt to re­light the burner under these conditions. The combustion chamber must first be purged before re-lighting.

Warning

!

Keep fingers away from the combustion air intake below the damper. The damper is actuated with sufficient force to cause
severe injury. Always make high and intermediate rate adjustments when the burner has reached low fire position. Do not
disturb the low fire setting.

1. If at any time during the operating cycle a flame failure occurs, the burner shuts down as in “Automatic Shutdown”,

with an additional post-purge, and the flame failure lamp is energized.

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A. The lockout switch on the flame safeguard control must be manually reset before the burner will fire again.

2. If a low water condition occurs, the burner shuts down as in “Automatic Shutdown”.

3. If a high or low gas pressure condition occurs while firing on gas, the burner shuts down as in “Automatic

Shutdown”.

A. Condition must be corrected and the respective gas pressure switch manually reset before the burner will fire

again on gas.

3.7 — Startup and Operating

Flame safeguard controls supplied with the burner can be of several different models with varying sequences, depend­ing upon the code requirements and mode of operation. Before attempting burner start-up, make certain that you are
familiar with the operation of the burner flame safeguard control and other components being used on the specific
application.This information can be downloaded from the control manufacturers website.

Warning

!

Failure to follow the startup procedure(s) described in this section may result in explosion, fire, property damage, and
personal injury. This procedure must be performed only by authorized and qualified personnel.

3.7.1 — Gas Burners (Bubble Test)

A gas valve leak test (Bubble Test) must be performed on the automatic safety shutoff valves located in the main gas

train prior to any initial commissioning or subsequent maintenance of the burner and gas train systems, where
automatic valve proving systems interlocked with the main burner safety control are not provided. This test should be
performed periodically to ensure no leakage of valves in their closed or de-energized position (refer to valve
manufacturers procedures).

The unit should be taken out of service if the unit fails any part of the gas valve leak test. Any defective part must be

replaced prior to putting the equipment back into service.

1. Close the main gas valve.

2. Make sure the ON-OFF switch is in the “OFF” position and the fuel selector switch is turned to “GAS.”

3. Actuate the manual reset button of the flame safeguard control to close the safety switch contacts.

4. Set the MANUAL-AUTO switch in the “MANUAL” position.

5. Set the manual potentiometer in the low fire position.

6. Partially open the leak test gas valve.

7. Set the ON-OFF switch to “ON.” The burner will start and pre-purge. After pre-purge, the ignition transformer and

the main solenoid are energized.

8. On initial startup it is recommended that the main gas shutoff cock remains partially closed until the programmer has

cycled through pre-purge and ignition sequence. Then determine that the main gas valve opens. When this is
confirmed, turn the burner switch “OFF” and let the programmer finish its cycle.

9. Check to see that the gas valve has closed tightly. If ignition does not occur, turn the burner switch “OFF” and allow

the programmer to recycle for a new ignition trial.Turn the burner “ON”, when the flame relay pulls in, the slow
opening, motorized, main gas valve is energized. The main flame should ignite at this time. The gas valve and air
damper continue advancing until high fire is reached.

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Operation

10. Do not repeat unsuccessful light off attempts without rechecking burner adjustment. Vent fuel vapors from the

combustion chamber after each unsuccessful light off attempt.

11. Set the gas low fire rate by adjusting the gas butterfly valve, or gas ratio regulator and blower speed.

12. When low fire is adjusted, slowly increase the rate to high fire. Allow the heating vessel to slowly reach normal

operating pressure or temperature.

13. Drive the burner to the high fire position. Check low and high fire at this point using combustion instruments.

14. Restart several times to be sure the low and high fire setting is suitable. Readjust if necessary. Never start the burner

with fuel vapor in the furnace. In case of an emergency, open the main power switches and close all fuel valves.

15. Do not disturb established low fire adjustment. Allow the burner to return to low fire position before adjusting high

or intermediate settings.

High fire combustion analysis typically is 3% to 4% O

. Low fire combustion analysis typically is 6% to 8% O2. When

2

conditions covered above are assured, refer to Sections 3.8 and 3.9.

3.7.2 — Burners Designed for On-Off Operation

Adjust main gas regulator and slow opening valve to achieve high fire and smooth ignition.

3.7.3 — Burners Designed for Low-High-Low Operation

1. Plumb the Kromschroeder VAV valve port PF to the front of the furnace using 861-00259 aluminum tubing and

appropriate associated hardware. Make sure the VAV PL port is plumb to the burner.

2. The UGB Board switch SW4 (High Fire Fan Speed) and SW2 (Low Fire Fan Speed) should already be factory set to

F and 5 respectively. Similarly the UGB Board dip switches should also be factory set (S1-1 on, S1-2 off, S1-3 off,
S1-4 on) and jumper JP2 should be removed.

3. Ensure that the high/low fire control is off (open) so that the high fire relay CR2 is also off. Turn the burner switch

on allowing the burner to cycle through its sequence purging and lighting off. The burner will now be at light-off/
low fire. With an Allen wrench adjust the dial on the bottom left of the Kromschroeder VAV valve to achieve
desired combustion.

4. Allow the high/low fire control to close (on) so that the high fire relay CR2 is also on. Turn the burner switch on

allowing the burner to cycle through its sequence purging and lighting off. The burner will now be at high fire. With
an Allen wrench adjust the dial on the bottom right of the Kromschroeder VAV valve to achieve desired
combustion.

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LIGHT OFF / LOW FIRE

ADJUSTMENT

HIGH FIRE
ADJUSTMENT

"PL"
CONNECT TO
BURNER

"PF"
CONNECT TO
BOILER

750-00518-000

CONNECT "PL" HERE

GAS CONNECTION

750-00518-000

FIGURE 3-1. Kromschroeder VAV valve

J3

ON

SW1

OFF

1

34

2

JUMPER
ON

SW2

SW4

DIP SWITCHES
1 & 4 ON
2 & 3 OFF

SET TO 9

SET TO F

750-00518-000

JUMPER

OFF

J6

JP2

J4

JUMPER

SET TO 3

J5

JP1

P6

FIGURE 3-2. UGB Board

3.7.4 — Burners Designed for Full Modulation Operation

Ensure power is supplied to the burner before attempting to commission the fuel curve.

1. Hold the F and A button to access the parameters (password is YYYYY).

2. Using the + and the - buttons to navigate, go to parameter 400.

3. Use the ¿ and + buttons to advance until the phase screen is displayed (PHXX).

4. Turn the burner switch on and burner will advance to phase 36 and purge.

5. After purge is complete, the burner will modulate to its light-off point (P0).

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Operation

6. Set the light-off point by adjusting the air (hold the F and A buttons while using + or - to adjust the actuator). Fan

speed at light-off should be 20-30% for Q6 and Q8 models. The butterfly valve should be between 0-10º.

7. Use the + button to advance the burner to light the main fuel.

8. Once the main fuel is lit, use the + and - buttons to cycle through the fuel curve points. P1 (low fire) to P9 (high fire)

and adjust each point for proper combustion.

9. Verify that each point has been correctly set by navigating to each point and waiting for the display to stop blinking

at each point. (Check O

levels and make sure O2 is higher than 3%).

2

10. Once all points have been set and verified, escape back to the home screen by pressing both the + and the - buttons

at the same time until the home screen appears.

11. If necessary, to enter the manual mode, hold the F button until the display says “load” (flashing indicates manual

mode). While still holding the F button, use + and - to adjust the modulation rate. To exit, hold ESC (+ and -) until
the whole display blinks (solid indicates auto mode).

12. Refer to the Siemens LMV37 manual for a detailed commission sequence.

After the Siemens LMV37 has been installed and commissioned, the person responsible for the system must document
the parameterized values and settings (e.g. curve characteristics) used for air-fuel ratio control. This data can be printed
out with the help of the Siemens ACS410 PC software, for example, or must be written down. This document must be
kept in a safe place and checked by the expert.

DEMAND FAN IGNITION

POWER

W

AG

FUEL

FLAME

FAILURE

R

LOAD

MODULATION

STATUS PHASE OP
(ERATE)

RESET

(FAULT HISTORY)

Loc:c 3 AIR PRESSURE
Loc:c 20 LOW GAS
Loc:c 21 HIGH GAS
Loc:c 22 SAFETY LOOP (OFF S)
Loc:c 2 FLAME FAILURE
Loc:c 87 SERVO FAILURE
Loc:c 167 MANUAL LOCKOUT

FIGURE 3-3. Siemens AZL Display Illustration

Warning

!

On the OEM level of the Siemens LMV37 parameter settings other than those specified in the application standards can be
made. For this reason, check whether the parameter settings made are in compliance with the relevant state and local
application standards/jurisdictions or whether the respective plant demands special approval.

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3.7.5 — Optional Temperature/Pressure Control Kit

Optional temperature/pressure control kits are available for the Q series. Figure 3-4 is an installation drawing for a
Siemens RWF10 or RWF50 temperature/pressure control kit. Refer to the manufacturers operation and maintenance
manual for the installation and set-up procedures for all other temperature/pressure controls.

A

DETAIL A

SCALE .625:1

880-06270-001

FIGURE 3-4. Temperature Control Installation Example (Siemens)

3.8 — Normal Operation

In automatic operation, the operating cycle always proceeds sequentially through pre-purge, main flame ignition, run,
and post-purge. The length of the purge and ignition trial vary according to the type of programmer used.

During the run cycle, burner input is regulated to the load demand by the modulating pressure or temperature control on
the boiler. The burner will continue to modulate until the operating pressure or temperature is reached.

Programmer control operation should be tested when the burner is initially placed into service, when a control is
replaced, and at scheduled intervals in the maintenance program.

Refer to adjustment procedures and maintenance instruction given in Chapters 4 and 5.

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Operation

3.9 — Shutdown

When the operating limit control setting is reached or the burner switch is in the “OFF” position, the following
sequence occurs:

1. The fuel valve(s) de-energize and the flame extinguishes. The blower motor continues running during post-purge.

2. At the end of post-purge, the blower motor is de-energized.

3. The programmer returns to its starting position and stops. The unit is ready to restart.

Abnormal shutdown might result from motor overload, flame outage, low water, current or fuel supply interruption,
combustion air pressure below minimum level, tripped circuit breakers, blown fuses, or other interlock devices. Check
for the cause and make the necessary corrections before restarting the burner.

Safety shutdown caused by ignition or flame failure will actuate a red indicator light and energize an audible alarm (if
so equipped). If the programmer has a non-recycling interlock circuit, any interruption in this circuit during the pre­purge or firing cycle will cause a safety shutdown. This type of shutdown requires manual reset of the programming
control and must be corrected before operation can be resumed.

Warning

!

An ultraviolet flame sensor electrical spark interference test must be performed after final adjustment. See Section 3.2 in
this chapter for additional information.

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

Item Check

Boiler Check the boiler water level. Be sure all boiler valves are installed correctly and positioned properly. Set the

high limit control slightly above the desired temperature. Set modulating controls at the desired temperature
or pressure.

Burner Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and

the control circuit. Check the direction or rotation of the motors. Open the housing to check the electrode
setting.

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

Check the control actuator for proper movement.

Check the air shutter and adjust low fire setting.

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CHAPTER 4 Adjustments

4.1 — Overview

While each burner is tested at the factory for correct operation before shipment, variable conditions such as burning
characteristics of the fuel used and operating load conditions may require further adjustment after installation to assure
maximum operating efficiency.

Prior to placing the boiler into initial service, a complete inspection should be made of all controls, connecting piping,
wiring and all fastenings such as nuts, bolts and setscrews to be sure that no damage or misadjustments occurred during
shipping and installation.

A combustion efficiency analysis made during the initial start-up will help to determine what additional adjustments
are required in a particular installation.

4.2 — Combustion Adjustment on Gas

Efficient combustion cannot be properly judged by flame appearance, although it may help in making preliminary
settings.

The proper settings of air-fuel ratios must be determined by flue gas analysis. Combustion gas analysis indicates the air
to fuel ratio and the degree of complete combustion. Instruments are available to measure carbon dioxide (CO
oxygen (O

), and carbon monoxide (CO).

2

4.2.1 — Stack Temperature

Net stack temperature is obtained by subtracting the ambient temperature from the flue gas temperature. A high net
stack temperature indicates wasted heat. Stack temperature should be as low as possible without causing flue gas
condensation.

Stack heat loss can be reduced by decreasing either the temperature or the volume of the flue gas, or both. Flue gas
temperature is reduced by improving heat transfer or by reducing excess combustion air. A certain amount of excess air
is necessary to complete combustion. More efficient burners require minimum excess air.

2

),

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4.2.2 — Gas Adjustments

Adjustments

Low fire combustion analysis typically is 7% to 9% O

and less than .04% CO (400 ppm). A high fire reading typically

2

is 3% to 4% O2 and less than .04% CO.

4.2.3 — Honeywell V48A Gas Valve Adjustment

NOTE: The gas train components ship loose, therefore, the bleed valve will need to be installed and adjusted in the field.

1. The bleed valve screw should be open one (1) turn counterclockwise from the fully closed position as a starting

point.

2. Adjust the bleed valve in 1/4 turn counterclockwise increments until the V48A gas valve opens at the desired open-

ing speed for a smooth main flame ignition.

3. The burner should be cycled between adjustments.

4.3 — Electrical Interference Test

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

Gas Fired Test:

1. Close the manual gas valves.

2. Start the burner, the flame relay should not pull in (be energized).

3. Upon completion of successful test, proceed with startup procedures.

4. Reconnect the power supply and proceed with startup procedures.

4.4 — Gas System

4.4.1 — Gas Pressure

Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas train and furnace
pressure while running at full input. Refer to nameplate inside control panel for gas pressure requirements at train inlet
and manifold. The pressures listed are based on nominal 1000 Btu/cu ft. natural gas at elevations up to 2000 feet above
sea level.

4.4.2 — Gas Flow

The volume of gas is measured in cubic feet as determined by a meter reading. The gas flow rate required depends on
the heating value (Btu/cu ft.). The supplying utility can provide this information as well as pressure correction factors.
To determine the required number of cubic feet per hour of gas, divide burner input (Btu/hr) by the heating value (Btu/
cu ft.).

NOTE: When checking the input rate, Make sure no other equipment is operating on the same meter.

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Adjustments

4.4.3 — Direct Spark Ignition Flame Adjustment

The ignition flame is regulated by adjusting the pressure setting of the main regulator and adjusting the butterfly valve

setting. Normal setting is 0.5” W.C. when the burner is on. The flame must be sufficient to be proven by the flame
detector.

Although it is possible to visibly adjust the size of the flame, obtain a proper DC volt or microamp reading of the flame

signal.

The flame safeguard amplifier has a meter jack for this purpose. At initial startup and during planned maintenance, test

the flame signal, burner turndown, and safety switch lockout.

Warning

!

An ultra-violet flame sensor electrical spark interference test must be performed after final adjustment. See Section 4.3 of
this chapter for additional information.

4.4.4 — Main Gas Pressure Regulator

The gas pressure required at the burner manifold is the pressure that is required to fire the burner at its rated capacity. The gas

pressure regulator must be adjusted to achieve this pressure to assure full input. Refer to manufacturer's literature for regulator
adjustment.

4.4.5 — Low Gas Pressure Switch

Turn adjusting screw until indicator moves to a pressure setting slightly below the operating gas pressure. The control

will break a circuit if pressure is below this set point. The control should be finally adjusted to prevent operation with
low gas pressure, but not at a pressure so close to normal operating pressure that unnecessary shutdowns occur. The
switch must be manually reset after tripping. To reset, allow gas pressure to rise and press the manual reset button.

4.4.6 — High Gas Pressure Switch

Turn the adjusting screw until the indicator moves to a pressure setting slightly above the maximum operating gas

pressure. The control will break a circuit if pressure exceeds this value. The control should be adjusted to prevent
operation with excessive gas pressure, but not at a pressure so close to normal operating pressure that unnecessary
shutdowns occur.This switch must be manually reset after tripping. To reset, allow gas pressure to drop and press the
manual reset button.

4.4.7 — Gas Combustion Adjustment

After operating for a sufficient period of time to assure a warm boiler, make adjustments for most efficient

combustion.The gas ratio regulator or the butterfly gas valve directly controls the rate of flow. The low fire light-off
setting should be regarded as preliminary until proper gas pressure for high fire operation is established.

Determine the actual gas flow from a meter reading at high fire. With the butterfly valve open and with regulated gas
pressure set, the actual flow rate should be quite close to the required input. If corrections are necessary, increase or
decrease the gas pressure by adjusting the gas pressure regulator, following manufacturer's directions for regulator
adjustment.

When proper gas flow is obtained, take a flue gas analysis reading.

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Adjustments

With the high fire air-fuel ratio established, the gas pressure regulator needs no further adjusting.

Recheck low fire and adjust if necessary.

Proper setting of the air-fuel ratios at all rates must be determined by combustion analysis. See Section 4.2 of this
chapter for additional information.

NOTE: Check for CO through the entire firing range.

4.5 — Parallel Positioning Adjustment

For parallel positioning systems refer to the control manufacturer's documentation and to the accompanying wiring
diagram for information on adjusting the system. In a properly tuned parallel positioning system the independent
actuators for fuel, will be coordinated to provide optimum combustion throughout the firing range.

Warning

!

Keep fingers away from the air intake below the damper. The damper is actuated with sufficient force to cause severe
injury.

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CHAPTER 5 Maintenance

5.1 — Overview

Warning

!

Any cover plates, enclosures, or guards anchored to the burner, or any burner related equipment, must remain in position at
all times. Only during maintenance and service shutdown can these cover plates, enclosures, or guards be removed. They
must be replaced, and securely anchored before testing, adjusting, or running the burner or burner related equipment.

Caution

!

It is important that you provide support for the housing when in the open position to prevent damage to the hinges and
other components.

A maintenance program avoids unnecessary down time, costly repairs, and promotes safety. It is recommended that a
record be maintained of daily, weekly, monthly, and yearly maintenance activities.

Electrical and mechanical devices require systematic and periodic inspection and maintenance. Any “automatic”
features do not relieve the operator from responsibility, but rather free him from certain repetitive chores, providing
time for upkeep and maintenance.

Unusual noise, improper gauge reading, leak, sign of overheating, etc., can indicate a developing malfunction,
requiring corrective action.

5.2 — Control System

Most operating controls require very little maintenance beyond regular inspection. Examine electrical connections.
Keep the controls clean. Remove any dust from the interior of the control. Covers should be left on controls at all times.
Keep the control cabinet doors closed. Dust and dirt can damage motor starters and relay contacts. Starter contacts are
plated with silver and are not harmed by discoloration. Never use files or abrasive materials such as sandpaper on
contact points.

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5-1

Maintenance

5.2.1 — Programming Control

This control requires no adjustment, nor should any attempt be made to alter contact settings or timing logic. Those
programmers with contacts may require occasional cleaning. If so, follow instructions given in the manufacturer's
bulletin. Never use abrasive materials. The manufacturer's bulletin also contains troubleshooting information. The
flame detector lens should be cleaned as often as conditions demand. A periodic safety check procedure should be
established to test the complete safeguard system. Tests should verify safety shutdown with a safety lock out upon
failure to ignite the pilot or the main flame, and upon loss of flame. Each of these conditions should be checked on a
scheduled basis. The safety check procedures are contained in the manufacturer's bulletin.

5.3 — Impeller

The blower uses a backward curved impeller and a die cast aluminium housing. The blower requires no adjustment.

5.4 — Firing Head Inspection

Release the side cover and pull the firing head out of the burner housing. Inspect the flame scanner lens to be sure it is
clean. Inspect the lead wire to the ignition electrode. It must be firmly attached and the insulation should be clean and
free of cracks.

5.5 — Air Filter Inspection

The air filter if provided needs to be inspected daily and replaced on an as needed basis.

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Maintenance

5.6 — Ignition Electrode & Flame Rod

COVER

FLAME ROD

0.25 - 0.125

ORIFICE PLATE

FLAME ROD

BAFFLE PLATE

BAFFLE PLATE

ORIFICE PLATE

.16

ELECTRODE

ORIFICE PLATE

BAFFLE PLATE

ELECTRODE

750-00510-000

(TIP IS FLUSH WITH

FACE OF BAFFLE PLATE)

ELECTRODE

FIGURE 5-1. Ignition Electrode Gap and Flame Rod Orientation

The ignition transformer requires little attention other than making sure the ignition wire is firmly attached to the

transformer and the electrode. Be sure the wire insulation is in good condition and not grounded. Failure to keep the
ignition electrode clean and properly set can cause faulty operation. The electrode assembly is supported by a socket in
the diffuser and gas inlet tube. No adjustment is required except proper positioning of the electrode wire.

5.7 — Flame Scanner

The scanner must be clean. Even a small amount of contamination will reduce the flame signal. Wipe the scanner lens

with a clean soft cloth.

5.8 — Firing Rate Controls

Make sure all connections are tight. Adjust if necessary. Perform a combustion test as explained in Chapter 4, and
readjust the burner if necessary.

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5-3

Maintenance

5.9 — Burner Mounting Inspection

The seal between the burner flange and furnace front plate must not permit combustion gases to escape. Periodic
inspection is important. Replace the gasket if necessary. Inspect the burner head for signs of discoloration. A change
the head color paint might indicate gas leakage between the burner flange and the boiler refractory. If leakage occurs,
refer to Chapter 2, Section 2.4, for proper sealing procedure.

5.10 — Gas System

Caution

!

Disconnect all power before servicing the valves.

5.10.1 — Motorized Main Gas Valves

Should the valve fail to operate, check for voltage at the valve. Make certain that the main shutoff cock is closed prior
to testing. The actuator is not field repairable nor should it be disassembled. Replace the actuator if the valve fails to
operate. After replacement, cycle the valve with the fuel shutoff to determine that it opens and closes. If the valve has a
visual indicator, observe its position for correct operation.

5.10.2 — Solenoid Valves

A slight hum from the solenoid is normal when the coil is energized. Should the valve fail to operate, check that there
is voltage at the valve coil. If there is no voltage at coil, check for loose wiring connections. If there is proper voltage at
the valve coil and the valve still fails to open, replace the coil. Refer to manufacturer's bulletin for correct procedure in
coil replacement.

Should it become necessary to replace the complete valve, be sure that the flow is in the direction of the arrow on the
body.

Test for gas leaks and check valve action several times to ensure proper operation before attempting to relight the
burner.

5.11 — Electrical System

Because of the many types of flame safeguard systems applicable to this equipment, complete descriptions of all burner
electrical systems are beyond the scope of this manual. An individual electrical schematic drawing is shipped with each
burner and complete operation and troubleshooting instructions are available from the various flame safeguard system
manufacturers.

5.11.1 — Electric Motors

Motor supply voltage must not vary more than 10 percent from nameplate ratings. At initial startup and at least once a
year thereafter, check the motor current with a meter while the burner is in high fire position. If the reading exceeds the
nameplate rating plus service factor, determine the cause and correct it immediately. In dusty locations, clean the motor
regularly to assure adequate cooling. Lubricate in accordance with the manufacturer's instructions.

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Maintenance

5.12 — Extended Shutdown

When shutting down the burner for an extended period of time, the operator should use the following general guidelines

to protect the burner from its surrounding elements. This will add to the operating life of the burner.

1. Turn the main electrical disconnect switch to the burner to “OFF.”

2. Close all main fuel valves.

3. If the burner operates in a damp environment, cover it with plastic to protect all electrical components from

moisture. Remove the flame safeguard control and store in a dry atmosphere.

5.13 — Recommended Maintenance Schedule

Item Service By Remarks

DAILY

Gauges, Monitors, Indicators Operator Make visual inspection and record readings in log.

Instrument & Equipment Settings Operator Make visual check against recommended specifications.

Low Water, Fuel Cutoff & Alarms Operator Refer to instructions.

Air Filter Operator Refer to instructions.

WEEKLY

Firing Rate Control Operator Verify factory settings.

Igniter Operator Make visual inspection. Check flame signal strength.

Main Fuel Valves Operator Open limit switch. Make audible and visual check. Check valve position

indicators, and check fuel meters.

Flame Failure Controls Operator Close manual fuel supply valve(s). Check safety shutdown timing. Record

in log.

Flame Signal Strength Controls Operator Read and log the flame signal for main flame. Notify Service if readings

are very high, very low, or fluctuating.

MONTHLY

Low Fan Pressure Interlock Operator Manually adjust until switch opens.

High & Low Gas Pressure Interlocks Operator Refer to instructions. Manually adjust until switch opens.

Scanner Operator Check, inspect, and clean for soot buildup.

ANNUALLY

Impeller Operator Inspect and clean the combustion impeller.

Combustion Test Service Tech Perform a complete combustion test. Adjust burner if necessary. Read and

log data.

Operating Controls Service Tech Refer to instructions.

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5-5

Maintenance

5-6

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CHAPTER 6 Troubleshooting

Warning

!

Troubleshooting should be performed only by personnel who are familiar with the equipment and who have read and
understood the contents of this manual. Failure to follow these instructions could result in serious personal injury or death.

Warning

!

Disconnect and lockout the main power supply in order to avoid the hazard of electrical shock. Failure to follow these
instructions could result in serious personal injury or death.

6.1 — Awareness

Chapter 6 assumes that:

• The unit in question has been properly installed and that it has been running for some time.

• The operator has become thoroughly familiar with both the burner and the manual by this time.

The points set forth under each heading are brief, possible causes, suggestions or clues to simplify locating the source
of the trouble. Methods of correcting the trouble, once it has been identified, may be found elsewhere in this manual.

If the burner will not start or operate properly, the Troubleshooting section should be referred to for assistance in
pinpointing problems that may not be readily apparent.

The program relay has the capability to self-diagnose and to display a code or message that indicates the failure
condition. Refer to the control bulletin for specifics and suggested remedies.

Familiarity with the programmer and other controls in the system may be obtained by studying the contents of this
manual. Knowledge of the system and its controls will make trouble shooting that much easier. Costly downtime or
delays can be prevented by systematic checks of actual operation against the normal sequence to determine the stage at
which performance deviates from normal. Following a set routine may help to detect obvious conditions, often ones
that are relatively simple to correct.

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6-1

Troubleshooting

If an obvious condition is not apparent, check the continuity of each circuit with a voltmeter or test lamp. Each circuit
can be checked and the fault isolated and corrected. In most cases, circuit-checking can be accomplished between
appropriate terminal on the terminal boards in the control cabinet or entrance box. Refer to the wiring schematic
supplied for terminal identification.

Never attempt to circumvent any of the safety features.

Warning

!

The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to restart.
Failure to do so may result in serious personal injury or death.

Warning

!

Do not repeat unsuccessful lighting attempts without rechecking the burner adjustments. Damage to the boiler or serious
personal injury or death may result.

Warning

!

Do not attempt to start the main burner if the combustion chamber is hot and/or if gas is present in the furnace or flue
passages. Promptly correct any conditions causing leakage. Failure to follow these instructions could result in serious
personal injury or death.

6.2 — Emergency Shutdown

In case of emergency, shut down the burner by turning the ON-OFF switch to the “OFF” position. Turn the fuel
selector switch to the “OFF” position. Shut off the main manual fuel shut off valves on the fuel supply line. The unit
can also be shut down with the main electrical power disconnect. Inspect the burner carefully and troubleshoot before
re-starting the unit. Follow instructions in Chapter 3 for starting and operating.

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Troubleshooting

6.3 — Problem/Possible Causes

Problem Possible Causes

Burner Does Not Start 1. No voltage at the program relay power input terminals.

a. Main disconnect switch open.

b. Blown control circuit fuse.

c. Loose or broken electrical connection.

2. Program relay safety switch requires resetting.

3. Limit circuit not completed - no voltage at end of limit circuit program relay terminal.

a. Pressure or temperature is above setting of operation control

b. Water below required level. Low-water light (and alarm horn) should indicate this

condition. Check manual reset button, if provided, on low-water control.

c. Fuel pressure must be within settings of low pressure and high pressure switches.

d. Check burner air proving switch and high-fire limit switch.

4. Fuel valve interlock circuit not completed.

a. Fuel valve auxiliary switch not closed.

No Ignition 1. Lack of spark.

a. Electrode grounded or porcelain cracked.

b. Improper electrode setting.

c. Loose terminal on ignition cable, cable shorted.

d. Inoperative ignition transformer.

e. Insufficient or no voltage at ignition circuit terminal.

2. Spark but no flame.

a. Lack of fuel - no gas pressure, closed valve, empty tank, broken line, etc.

3. Low-fire switch open in low-fire proving circuit.

a. Damper motor not closed, slipped cam, defective switch.

b. Damper jammed or linkage binding.

4. Running interlock circuit not completed.

a. Combustion air proving switches defective or not properly set.

b. Motor starter interlock contact not closed.

Problem Possible Causes

No Main Flame 1. Insufficient ignition flame.

2. Gas fired unit:

a. Manual gas cock closed.

b. Main gas valve inoperative.

c. Gas pressure regulator inoperative.

3. Flame detector defective, sight tube obstructed or lens dirty.

4. Insufficient or no voltage at main fuel valve circuit terminal.

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6-3

Problem Possible Causes

Burner Stays in Low-Fire 1. Pressure or temperature above modulating control setting.

2. Manual-automatic switch in wrong position.

3. Inoperative modulating motor.

4. Defective modulating control.

Shutdown Occurs During
Firing

1. Loss or stoppage of fuel supply.

2. Defective fuel valve, loose electrical connection.

3. Flame detector weak or defective.

4. Scanner lens dirty or sight tube obstructed.

5. If the programmer lockout switch has not tripped, check the limit circuit for an opened
safety control.

6. If the programmer lockout switch has tripped:

a. Check fuel lines and valves.

b. Check flame detector.

c. Check for open circuit in running interlock circuit.

d. The flame failure light is energized by ignition failure, main flame failure, inadequate

flame signal, or open control in the running interlock circuit.

7. Improper air/fuel ratio (lean fire).

a. Fluctuating fuel supply.

Temporary obstruction in the fuel line.

Temporary drop in gas pressure.

8. Interlock device inoperative or defective.

Actuator Does Not Oper­ate

1. Manual/automatic switch in wrong position.

2. Motor does not drive to open or close during pre-purge or close on burner shutdown.

a. Motor defective.

b. Loose electrical connection.

c. Damper motor transformer defective.

3. Motor does not operate on demand.

a. Manual/automatic switch in wrong position.

b. Modulating control improperly set or inoperative.

c. Motor defective.

d. Loose electrical connection.

e. Damper motor transformer defective.

Troubleshooting

6-4

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Startup/Service Report

The following information should be filled in by the service technician at startup or after any adjustment to the burner.

A copy of the startup report MUST be forwarded to C-B in order to validate the warranty of the burner.

Burner Model _______________ Serial Number_______________ Startup Date_______________

Voltage Amperage

Electric Motors

Control Voltage

Blower Motor

Test Conducted

Firing Rate MMBtu/gph Aux. LWCO

Stack Temp (gross) º F High Water Cutoff

Room Temp º F Operating Limit

O2% High Limit

CO% Operating Control

CO (PPM) Stack Temp Interlock

NOx (PPM) Flame Failure

Smoke (Bacharach) N/A N/A N/A Combustion Air Switch

Combustion Eff.% High Purge Switch

Stack Draft “W.C. Low Fire Interlock

Furnace Pressure “W.C. Oil Pressure Switch N/A N/A

Blast Tube Pressure “W.C. Oil Valve w/P.O.C.

Steam Pressure PSIG

Water Temp º F High Gas Pressure Switch

Supply Oil Pressure PSIG N/A N/A N/A Low Gas Pressure Switch

Return Oil Pressure PSIG N/A N/A N/A

Vacuum Oil Pump “HG N/A N/A N/A Pilot Turndown Test N/A N/A

Oil Temp N/A N/A N/A Flame Signal Pilot N/A N/A

Atom. Air Pressure (For Low NOx Burners)

Gas Pressure @ Burner

Manifold “ W.C.

Center Gas Pressure “W.C. FGR Valve P.O.C. N/A N/A

Gas Pressure @ Regulator Inlet PSIG

Gas Pressure @ Regulator Outlet PSIG

Pilot Gas Pressure @ Regulator Outlet “ W.C. N/A N/A N/A

Flame Signal Main LOW 50% HIGH

L1 L2 L3 L1 L2 L3

Gas Control Check Test Set Point

Low 50% High

Inner Manifold

Outer Manifold FGR Line Purge Switch N/A N/A

Low Water Cutoff

Interlock

Gas Valve P.O.C.

Interlock

Blast Tube Temp

Interlock

N/A N/A

N/A N/A

Adjusted by:

Date:

Accepted by:

(Signature Required)

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Warranty Policy

Limited Warranty: The Company warrants that at the time of shipment, the equipment manufactured by it shall be
merchantable, free from defects in material and workmanship and shall possess the characteristics represented in
writing by the Company. The Company's warranty is conditioned upon the equipment being properly installed and
maintained and operated within the equipment's capacity under normal load conditions with competent supervised
operators.

Equipment, accessories, and other parts and components not manufactured by the Company are warranted only to the
extent of and by the original manufacturer's warranty to the Company. In no event shall such other manufacturer's
warranty create any more extensive warranty obligations of the Company to the Buyer than the Company's warranty
covering equipment manufactured by the Company.

Exclusions From Warranty: (I) THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, ORAL OR
EXPRESS OR IMPLIED, INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION OF
THE EQUIPMENT. THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE CONTAINED HEREIN
TO THE EXTENT PERMITTED BY THE LAW. THERE ARE NO IMPLIED WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE. THE PROVISIONS AS TO DURATION, WARRANTY ADJUSTMENT AND
LIMITATION OF LIABILITY SHALL BE THE SAME FOR BOTH IMPLIED WARRANTIES (IF ANY) AND
EXPRESSED WARRANTIES.

(II) The Company's warranty is solely as stated in (a) above and does not apply or extend, for example, to: expendable
item; ordinary wear and tear; altered units; units repaired by persons not expressly approved by the Company; materials
not of the Company's manufacture; or damage caused by accident, the elements, abuse, misuse, temporary heat,
overloading, or by erosive or corrosive substances or by the alien presence of oil, grease, scale, deposits or other
contaminants in the equipment.

Warranty Adjustment: Buyer must make claim of any breach of any warranty by written notice to the Company's
home office within thirty (30) days of the discovery of any defect. The Company agrees at its option to repair or
replace, BUT NOT INSTALL, F.O.B. Company's plant, any part or parts of the equipment which within twelve (12)
months from the date of initial operation but no more than eighteen (18) months from date of shipment shall prove the
Company's satisfaction (including return to the Company's plant, transportation prepaid, for inspection, if required by
the Company) to be defective within the above warranty. Any warranty adjustments made by the Company shall not
extend the initial warranty period set forth above. Expenses incurred by Buyer in replacing or repairing or returning the
equipment or any part or parts will not be reimbursed by the Company.

Spare and Replacement Parts Warranty Adjustment: The Company sells spare and replacement parts. This
subparagraph (10.4) is the warranty adjustment for such parts. Buyer must make claim of any breach of any spare or
replacement parts by written notice to the Company's home office within thirty (30) days of the discovery of any
alleged defect for all such parts manufactured by the company. The Company agrees at its option to repair or replace,
BUT NOT INSTALL, F.O.B. Company's plant, any part or parts or material it manufacture which, within one (1) year
from the date of shipment shall prove to Company's satisfaction (including return to the Company's plant,
transportation prepaid, for inspection, if required by the Company) to be defective within this part warranty. The
warranty and warranty period for spare and replacement parts not manufactured by the company (purchased by the
Company, from third party suppliers) shall be limited to the warranty and warranty adjustment extended to the
Company by the original manufacturer of such parts; In no event shall such other manufacturer's warranty create any
more extensive warranty obligations of the Company to the Buyer for such parts than the Company's warranty

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ProFire Q Series Manual

adjustment covering part manufactured by the Company as set forth in this subparagraph (10.4). Expenses incurred by
Buyer in replacing or repairing or returning the spare or replacement parts will not be reimbursed by the Company.

Limitation of Liability: The above warranty adjustment set forth Buyer's exclusive remedy and the extent of the
Company's liability for breach of implied (if any) and express warranties, representations, instructions or defects from
any cause in connection with the sale or use of the equipment. THE COMPANY SHALL NOT BE LIABLE FOR ANY
SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES OR FOR LOSS, DAMAGE OR EXPENSE, DIRECTLY
OR INDIRECTLY ARISING FROM THE USE OF THE EQUIPMENT OR FROM ANY OTHER CAUSE
WHETHER BASED ON WARRANTY (EXPRESS OR IMPLIED) OR TORT OR CONTRACT, and regardless of
any advice or recommendations that may have been rendered concerning the purchase, installation, or use of the
equipment.

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Web Address: http://www.cleaverbrooks.com