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Q6-055

CleaverBrooks Q6-130, Q6-075, Q6-055, Q6-100, Q8-175 Installation Operation & Maintenance

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Table Of Contents
ProFire Q
Full Modulation Burner
with UV flame detection
Installation
Operation
Maintenance
Manual Part No. 750-437 07/2019
Q SERIES
Linkageless Full Modulation Burner with UV Flame Detection
750-00516-000
Manual Number: 750-00437 Revision 07/2019
Information to be filled out by owner
Unit Serial Number:
Date of Installation:
Distributor Information
Name:
Address:
Phone Number:
Copyright © 2019 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 Cleaver-Brooks.
Cleaver-Brooks 351 21st Street Monroe, WI 53566 608-325-3141 cleaverbrooks.com
i
Q Series Installation, Operation, and Service Manual
Table of Contents
Preface iv
Specifications v
Dimensions vi
Spare Parts List vii
CHAPTER 1 Introduction 1-1
Description 1-1
Control Panel 1-2
Burner Control and Air Delivery 1-3
Direct Spark System 1-4
Firing Head 1-5
Gas System 1-6
CHAPTER 2 Installation 2-1
Burner Requirements 2-1
Factory and Field Wiring Overview 2-1
Draft Conditions 2-2
Combustion Air Supply 2-2
Combustion Chamber Recommendations 2-2
Firetube Refractory Front Plate Requirements 2-4
Support Bracket Installation 2-6
Gas Piping 2-6
Optional Ducted Combustion Air 2-7
Combustion Air Inlet Orifice Plate Installation 2-8
Installation Checklist 2-9
CHAPTER 3 Operation 3-1
Preparations for Starting 3-1
Burner Sequence Overview 3-2
Gas Pressure Regulator Setup 3-6
Gas Train Leak Test 3-6
Combustion Emissions and Efficiency 3-9
LMV3 Settings 3-10
Test and Set Gas Pressure Switches 3-19
Optional Heat Timer MCF Load Control 3-20
ii 750-437
Q Series Full Modulation
CHAPTER 4 Adjustments 4-1
Overview 4-1
Gas System 4-1
CHAPTER 5
CHAPTER 6 Troubleshooting 6-1
Maintenance 5-1
Overview 5-1
Control System 5-2
Impeller 5-2
Firing Head Inspection 5-2
Ignition Electrode 5-3
Flame Scanner 5-3
Firing Rate Controls 5-4
Burner Mounting Inspection 5-4
Gas System 5-4
Electrical System 5-4
Extended Shutdown 5-5
Recommended Maintenance Schedule 5-6
Awareness 6-1
Emergency Shutdown 6-2
Troubleshooting - General 6-3
LMV3 Diagnostics 6-4
Restoring LMV3 Parameters 6-22
Default Settings 6-24
STARTUP/SERVICE REPORT
WARRANTY POLICY
iii
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
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. Gas burning equipment shall be connected to flues having sufficient draft at all times to assure safe and proper operation of the burner.
Q Series burners are designed to burn gas only as defined by ASTM D396-2010 specifications.
iv 750-437
Q Series Full Modulation
Q Series Full Mod Linkageless - Standard Specifications
Minimum Gas Pressure Required in Inches Water Column, by Gas Train
Burner
Gas Input
Model
Q6-055 550 13 1/2 1.0 1.50 2.10 - - 2.10 - -
Q6-075 750 18 1/2 1.0 1.80 3.60 1.70 - 3.80 2.00 -
Q6-100 1,000 24 1/2 1.0 2.25 6.40 2.90 2.60 6.60 3.40 2.60
Q6-130 1,250 30 1/2 1.0 2.95 10.10 4.20 3.50 10.60 5.20 3.70
Q6-150 1,500 36 1/2 0.75 * 13.60 5.70 4.80 14.20 7.00 5.10
Q8-175 1,750 42 3/4 1.0 3.45 15.50 4.80 3.50 16.30 6.60 3.90
Q8-200 2,000 48 3/4 1.0 3.80 19.80 5.70 4.10 20.80 8.10 4.60
Q8-250 2,500 60 3/4 0.75 * - 8.60 5.90 32.20 12.20 6.80
MBtu/hr
BHP
@80%
Eff.
Blower
Motor HP
Furnace
Pressure
(“w.c.)
Air Inlet
Orifice Size
7
(in.)
1 PSI Inlet Rated UL Trains 10 PSI inlet Rated UL Trains
1.00" 1.50" 2.00" 1.00" 1.50" 2.00"
*Orifice not required
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.
6. Blower motor power: 115V / single phase / 60 Hz
7. See spare parts list for orifice plate part numbers.
Pressure Rating and Pipe Size
v
12X R
ØN
ØM
E
L
60°6X
30°
45°
90°4X
ØK
F
J
G
H
Q Series Full Modulation Linkageless Standard Dimensions
Accompanying dimensions are for layout purposes only.
Burner Model
DIM Q6 Q8
Length in inches
Overall burner length H 26 28 3/4
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 25 1/2 28
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 3 1/2 3 1/2
Diameter K 6 8
Mounting flange dimensions in inches
Outer diameter of mounting flange N 12 14
Bolt circle diameter M 8 7/8 10 7/8
Mounting flange slot width R 5/8 5/8
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 7 1/8 7 1/8
D
C
A
B
P
vi 750-437
Q Series Full Modulation
Q Series Spare Parts List
PART DESCRIPTION - COMMON PARTS BURNER SIZE PART NUMBER
Ignition Transformer Q6 & Q8 832-04117-000
Light Indicator, White Q6 & Q8 881-00136
Light Indicator, Red Q6 & Q8 881-00137
Light Indicator, Green Q6 & Q8 881-00138
Light Indicator, Amber Q6 & Q8 881-00139
Air Switch Q6 & Q8 836-01598-000
Electrode Q6 & Q8 435-00694-000
Ignition Cable Q6 & Q8 832-04118-000
Fuse, Blower Motor ATDR 6A Q6 832-01161
Fuse, Blower Motor ATDR 15A Q8 832-01168
Fuse, Control Circuit ATQR 6A Q6 & Q8 832-01210
PART DESCRIPTION - BURNER MODEL PARTS BURNER SIZE PART NUMBER
Baffle Weldment Q6 009-04280-000
Baffle Weldment Q8 009-04282-000
Burner Housing (Blast Tube) Q6 160-01003-000
Burner Housing (Blast Tube) Q8 160-01002-000
Flange Gasket Q6 853-02539-000
Flange Gasket Q8 853-02540-000
Fan/Blower Unit Q6 894-04076-000
Fan/Blower Unit Q8 894-04111-000
Cover Q6 019-02395-000
Cover Q8 019-02398-000
PART DESCRIPTION - CONTROL COMPONENTS BURNER SIZE PART NUMBER
Display, Siemens Q6 & Q8 833-05071-000
Cable, Display Siemens Q6 & Q8 826-00315-000
Controller, Siemens Q6 & Q8 833-09334-000
Valve, Butterfly, 1.5” Full Port Q6 & Q8 940-01254
Actuator, Fuel Valve Q6 & Q8 269-00166-000
Coupling Q6 & Q8 819-00337-000
UV Scanner Q6 & Q8 994-15597-000
vii
Q Series Spare Parts List Continued
PART DESCRIPTION - GAS TRAIN COMPONENTS GAS TRAIN OPTION PART NUMBER
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
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
Ball Valves 2” All Low Pressure 941-00128
Regulator, Maxitrol 210 1” All High Pressure 817-00674
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
PART DESCRIPTION - AIR INLET ORIFICE PLATE BURNER SIZE PART NUMBER
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
PART DESCRIPTION - DUCTED AIR INLET PARTS BURNER SIZE PART NUMBER
Instruction Drawing Q6 880-06261-000
Ducted-Air Adapter, 4" ID Q6 001-01680-000
Panel Side Plate With Ducted-Air Adapter Cutout Q6 136-04096-000
Instruction Drawing Q8 880-06262-000
Ducted-Air Adapter, 6" ID Q8 001-01681-000
Panel Side Plate With Ducted-Air Adapter Cutout Q8 136-04097-000
viii 750-437
Q Series Full Modulation
CHAPTER 1 Intr oduction
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.
The operator must be familiar with the individual functioning of all controls to understand the operations and procedures described in this manual.
1.1 — Description
Q-series full modulation units are forced-draft, direct-spark ignited, linkage-less burners controlled by an LMV37 programmer. They include safeguard functionality to insure the burner always returns to the ignition light-off position for startup.
The Q-series modulating burners provide 550 to 2,500 MBTU/hr (~13 to 60 boiler horse power) against furnace pressures of 0.75" w.c. or less (refer to burner specifications, page v). The Q6 has a 6" diameter firing head and can fire up to 1,500 MBTU/hr (~36 boiler horse power). The Q8 has an 8" diameter firing head and can fire up to 2,500 MBTU/hr (~60 boiler horse power). A field-installed air inlet orifice plate is required on Q6 burners firing below 1500 MBTU/hr and Q8 burners firing below 2500 MBTU/hr. See page viii for orifice plate part numbers.
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.
1-1
Introduction
1.2 — Control Panel
The Q burner control panel has the control switch, status indicator lamps and LMV37 remote display mounted on the panel exterior. The LMV37 control base, power supply, fusing and terminal strips are mounted on a subbase inside the panel.
6
5
4
3
2
1
7
750-00532-000
FIGURE 1-1. Control Panel
Item Component Details
1 On/Off Control Switch Burner power switch 2 Power Light White lamp; illuminates when the control circuit is powered 3 Ignition Light Amber lamp; illuminates when the ignition transformer is powered 4 Fuel Light Green lamp; illuminates when the main fuel valves are powered 5 Failure Light Red lamp; illuminates when an LMV37 lockout fault occurs 6 Blank Blank lamp port 7 Control Display Control interface and status indicator
1-2
Q Series Full Modulation
Introduction
1.3 — Burner Control and Air Delivery
5
6
1
3
750-00533-000
2
4
FIGURE 1-2. Burner Control and Air Delivery
Item Component Details
1 LMV37 Control Combined flame-safeguard (FSG) and fuel-air-ratio-controller 2 Fuse holders Motor and control circuit fusing 3 Terminal Strip Field wiring interface 4 Power Supply 24Vdc for motor control speed input 5 DC modulation control The unit is fully modulated in response to the command signal sent from the LMV37. 6 DC (EC*) motor-fan
*Electronically Commutated
DC variable speed motor-fan unit with integral electronic controls. The unit is energized by 115VAC power input.
1.3.1 — LMV37 Flame Safeguard and linkage-less fuel-air-ratio controller
The LMV37 incorporates burner sequencing functionality; flame detection; variable speed drive (VSD) control and fuel-air-ratio control. Flame is detected by UV flame scanner. The LMV37 can modulate the burner from low to high fire with servo control of the fuel metering valve and VSD electrical connection to the blower motor to control fan speed (air volume).
Warning
!
Read the LMV37 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
1.4 — Direct Spark System
Introduction
1
2
750-00531-000 3
FIGURE 1-3. Direct Spark System
Item Component Details
1 Ignition Transformer Step up secondary high voltage ignition transformer 2 Ignition Cable 25KV high tension ignition wire. 3 Igniter ø1/8" electrode with quick connect
1.5 — Firing Head
Access to the firing head is provided by the side access panel.
1-4
Q Series Full Modulation
Introduction
R
UV SCANNER
BURNER HOUSING
NUT
LOCK WASHER
UV SCANNER
BAFFLE PLATE
ELECTRODE
GAS MANIFOLD
ELECTRODE
ORIFICE PLATE
FIGURE 1-4. Burner Housing with a UV Scanner
SPRING PIN
ORIFICE PLATE
LOCK WASHER
STAND OFF
750-00509-001
750-00517-001
BAFFLE WELDMENT
LOCK WASHE
SCREW
SCREW
FIGURE 1-5. Burner Housing, Exploded View
1-5
Introduction
R
1.6 — Gas System
Gas is introduced into the combustion zone through multiple ports in the circular manifold. The full modulation burner's LMV37 controls both the combustion air and fuel metering: it meters the fuel in proportion to fan speed by adjusting the servo-driven gas metering butterfly valve.
Safety shutoff main gas valves are installed upstream of the gas-metering-butterfly valve and are controlled by the LMV37 to open and close at the proper time in the operating sequence. The Safety shutoff valve models may vary depending upon specific requirements.
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 Metering Butterfly Valve A servo-driven butterfly valve that controls the gas flow rate. Gas Automatic Safety Shutoff Valves (SSOV(s)) Electrically operated safety shutoff valve(s) that open to admit gas to the burner. Stan-
dard U.L. burners include one diaphragm gas valve and one solenoid gas valve.
Gas Regulator Regulates gas train pressure to specified pressure required at the inlet of the gas train.
Input is set by the main gas pressure regulator adjustment. Main Manual Gas Shutoff Valve A manual gas shutoff valve located at the gas train inlet (upstream of the regulator). Main Manual Leak Test Valve A second manual gas shutoff valve located between the SSOV(s) and metering butterfly
valve. It provides a means of testing for leakage through the SSOV(s).
SUPPLY GAS INTO GAS TRAIN INLET
MAIN
MANUAL
GAS
VALVE
GAS
REGULATOR
LOW
GAS
PRESSURE
SWITCH
GAS
AUTOMATIC
SAFETY
SHUTOFF
VALVE
GAS
AUTOMATIC
SAFETY
SHUTOFF
VALVE
HIGH
GAS
PRESSURE
SWITCH
750-00529-000
LEAK TEST
VALVE
MAIN
MANUAL
LEAK TEST
VALVE
GAS METERING
BUTTERFLY
VALVE
TO BURNE MANIFOLD INLET
FIGURE 1-6. Main Gas Train for Full Modulation (Q6-055 to Q8-250)
1.6.2 — Typical Gas Operation
Upon a call for heat and before flame ignition, the LMV37 flame safeguard starts the combustion air fan and confirms the gas metering butterfly valve is in the low-fire position. When the combustion air switch proves sufficient air, the control opens the gas safety shutoff valves. Provided the gas supply is connected and manual cocks are open, gas then flows through the main gas train and gas metering butterfly valve into the burner gas manifold. The gas streams out of the manifold through the multiple ports of the orifice plate (see Figure 1-5) and mixes with the fan-fed combustion air.
1-6
Q Series Full Modulation
Introduction
The control then powers the ignition electrode and initiates flame. The UV scanner and control confirms flame presence and the burner progresses to main-flame operation. Main flame continues while flame is proven; the external limit switches confirm good operating conditions, and a call for heat exists.
During main flame, the LMV37 receives a modulation input signal from a separate modulating controller that directs the LMV37 to provide more or less heat. When the call for heat is satisfied, the LMV37 moves the gas metering valve to the low-fire position and deenergizes the safety shutoff valves thereby shutting down the combustion process. A post-purge period follows, and the heat exchanger is purged with air. After post-purge, the burner returns to standby mode.
1-7
Introduction
1-8
Q Series Full Modulation
CHAPTER 2 Installation
2.1 — Burner Requirements
Proper installation requires the following:
• Sufficient air supply - allow enough clearance at the bottom of the burner to allow the burner's
fan to draw the high-fire air volume without difficulty.
Warning
!
• A gas-tight seal - for maximum safety, the burner/boiler mounting must be sealed to prevent the
escape of combustion products into the boiler room. When properly installed, the burner mounting flange and flange gasket will provide this seal. Make sure the flange gasket is installed uniformly flat between the burner flange and the boiler front plate. When the burner flange is tightened to the boiler, the gasket should be consistently flat around the entire flange circumference; an improperly installed gasket will not provide a seal.
• Proper burner support where needed - the front plates on many boilers, including some Scotch
Marine types, are not strong enough to support the burner's weight. The burner has provision for vertical support as detailed in Section 2.7.
2.2 — Factory and Field Wiring Overview
Electrical motor power and control circuit power are 115 volt, single phase, 60 cycle. Refer to the electrical schematic diagram shipped with the burner. The schematic is also attached to the inside of the control panel cover. Installer power connections are made at the control panel. Wiring from the panel to burner mounted components is completed at the factory. Field wiring from the burner panel to boiler controls, low water controls, and remotely located fuel valves is completed by the installer.
Caution
!
It is important to provide support for the panel cover when in the open position to prevent damage to the burner and enclosed components.
2-1
Installation
2.3 — 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.
2.4 — 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.
2.5 — Combustion Chamber Recommendations
The combustion chamber dimensions should be adequately sized to prevent flame impingements.
2.5.1 — Non-Firetube Applications
A
B
C
(MIN)
FLOOR
2-2
STANDARD
FIREBRICK
BLOCK INSULATION
Q Series Full Modulation
Installation
Combustion
Chamber Min.
Width (in.)
Chamber Min.
Burner Size
A
(in.)
B
(in.)
C
(in.)
Q6-055 3.5 6 10 8 24 Q6-075 3.5 6 10 10 24 Q6-100 3.5 6 10 12 24 Q6-130 3.5 6 10 12 36 Q6-150 3.5 6 10 14 36 Q8-175 3.5 8 12 14 48 Q8-200 3.5 8 12 16 48 Q8-250 3.5 8 12 16 48
FIGURE 2-1. Non-Firetube Combustion Chamber Dimensions
2.5.2 — Firetube Applications
Combustion
Length (in.)
Burner Model Boiler HP A (in.) B (in.)
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. Firetube Combustion Chamber Dimensions
A
B
2-3
Installation
2.6 — Refractory Front Plate Requirements
A dry oven refractory is required only to protect surfaces not adequately protected by free circulating water. Basic objectives of refractory installation include:
• Provide adequate combustion space
• Avoid flame impingement
• Protect surfaces not adequately water cooled
• Seal openings
Insulation should be provided between the refractory and the boiler base. Mineral wool or other material not likely to settle is preferred. Insulation should be used between the refractory and front plate. Firebrick or insulating firebrick should be set in high temperature bonding mortar with provision for expansion. Refer to
Figure 2-3 for refractory construction guidelines.
3.31
4.00 MIN.
"I"
45°
DIMENSION SIZE-6 SIZE-8
"A" 8.88 10.88 "B" 6.75 8.75 "C"
"C"
"D" "E" "F" "G" "H"
"I"
SIZED TO FIT BOILER
710-00897-000
A
45°
90°4X
"B"
"F"
"D"
"E"
"A"
P
3/8 STUDS
"G" x
1.25
P
"H"
A
FIGURE 2-3. Q Series Refractory Dimensions
To prevent leakage of combustion gases, the gasket must be resilient enough to seal any uneven areas between the burner and the front plate.
2-4
Caution
!
Q Series Full Modulation
Installation
Prepare the boiler front plate and burner insertion as follows:
1. Determine burner mounting height. Locate and scribe a level
horizontal centerline across the mounting face.
2. Locate and scribe a vertical centerline. Be sure stud locations
line up where studs will have full support. If they don’t, or if the opening is too large, a steel adapter plate, 3/8” minimum, may be welded or bolted in place. Suitable anchors should be provided to hold the refractory in place. The adapter plate must be properly sealed (using insulating rope gasket) to pre­vent leakage of combustion gases.
3. Insulate burner insertion as shown in Figure 2-4
•Apply tack spray on the insert portion of the firing head that will be wrapped.
•Wrap the insertion part of firing head with ceramic fiber blanket (Kaowool). The wrap should be installed such that it fills the 3/8” gap between the burner head outside diameter (OD) and the refractory internal diameter (ID).
•Wrap the Kaowool with masking tape-this makes the assembly easier to insert into the refractory. The wrapped Kaowool must provide a snug fit between the refractory and burner head. Rework if there are gaps.
•Trim off excess Kaowool.
•Apply ceramic-fiber rigidizer to the exposed Kaowool lip (see figure 2-5). Protect/mask off the burner head so the rigidizer only contacts the Kaowool lip; do not allow rigidizer to contact any other part of the burner head.
FIGURE 2-4. Insulate Insertion
Note: the tack spray and masking tape hold material in place while the burner is installed into the refractory. Following installation, heat exposure will burn away the tacking spray and masking tape.
4. Using insulating rope gasket, wrap the rope on the inside of
the bolt circle, looping the rope around the mounting studs.Set the burner into position for mounting and tighten into place. Standard burners are equipped with a four-hole mounting flange.
5. Permanently support the burner using the pipe support con-
nections.
FIGURE 2-5. Rigidize Exposed Lip
2-5
Installation
2.7 — Support Bracket Installation
Once the burner is installed, it must be supported by a suitable weight bearing surface. The burner is designed to use the supplied support bracket kit number 880-06384-000. The bracket should be mounted to the burner with the kit-supplied hardware.
A 3/4” NPS pipe, supplied by others, may then be cut to length and mounted so as to provide vertical support to the burner.
SUPPORT BRACKET (SUPPLIED WITH BURNER)
PIPE, 3/4" NPS (TOE)
SUPPLIED BY OTHERS)
750-00520-000
FIGURE 2-6. Support Bracket Installation
2.8 — Gas Piping
Gas service and house piping must supply the burner-required gas volume and pressure to 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).
Full modulation gas train components upstream of the butterfly valve that are shipped loose should be mounted by the installer as close to the burner as practical. Normally, the gas train is ordered to suit a particular code or insurance regulation, such as Underwriters Laboratories Inc., CGA, or Factory Mutual.
Arrange gas piping to the burner so that the burner is accessible for servicing without requiring train disassembly.
The gas piping must be internally clean and free of foreign material. Before using in service, a leak test must be performed.
2-6
Q Series Full Modulation
Installation
2.9 — Optional Ducted Combustion Air
An optional adapter port and slotted side panel allow combustion air to be ducted into the burner. The Q6 arrangement is a 4" OD inlet while the Q8 is a 6" OD inlet setup.
To equip the burner for ducted combustion air (item numbers refer to Figure 2-7):
• Change the side cover
1. Remove the cover lock-down thumb screw (Item 3).
2. Open the control cover (keep cover supported to prevent damage to it).
3. Remove the control panel side cover but retain the fasteners as they will be reused.
4. Install the slotted side cover (Item 2).
5. Replace the thumb screw (Item 3) to the position shown in Figure 2-7.
• Install the air inlet adapter NOTE: If orifice plate required (Section 2.10) install between the blower and air inlet adapter.
1. Remove the (6) bolts from the fan-assembly inlet collar and air-pressure sensing line
2. Align the adapter (Item 1) and air-pressure sensing line bracket then replace and secure the 6 bolts. Use a
medium thread locker such as Loctite Blue to assure secure retention.
2
1
FIGURE 2-7. Ducted Combustion Air
3
880-06262-000
2-7
Installation
2.10 — Combustion Air Inlet Orifice Plate Installation
The Q burner size 6 and 8 use air-inlet-orifice plates to limit combustion air to the maximum firing rate needed with respect to an application. The Q6 has a maximum rating of 1,500,000 BTU/HR. When used for the maximum rate an air-inlet-orifice plate is not used. The same is true of the Q8 when used at its maximum rating of 2,500,000 BTU/HR. For other firing rates, the chart below identifies the air-inlet orifice plate required:
TABLE 2- 1. Air Inlet Orifice Plate Application
Model Burner BTU/HR rating Air inlet Plate Part Number Orifice Diameter (in)
550,000 059-11448-000 1.50
750,000 059-11449-000 1.80
Q6
Q8
1,000,000 059-11450-000 2.25
1,300,000 059-11452-000 2.95
1,500,000 no orifice plate used -
1,750,000 059-11457-000 3.45
2,000,000 059-11458-000 3.80
2,500,000 no orifice plate used -
If an orifice plate is required, Install the provided plate to the blower assembly as shown in Figure 2-8 below. Remove the existing (6) bolts from the fan-assembly inlet collar and air-pressure sensing line. Align the plate and air-inlet sensing line then replace the (6) bolts. Use a medium thread locker such as Loctite Blue to assure secure retention.
2-8
FIGURE 2-8. Inlet Orifice Plate Installation
Q Series Full Modulation
Installation
2.11 — 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 power 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.
It is the installer’s 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.
2-9
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