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- Page 1 Table Of Contents ProFire Q Burner Gas Only Installation Operation Maintenance Manual Part No. 750-370 01/2016...
- Page 3 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:...
- Page 4 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...
- Page 5 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.
- Page 6 Standard Q Series Specifications Min. Gas Pressure Low Gas Fresh Blower Furnace Train Pressure Gas Train Pressure Air Inlet Air Inlet Burner Input @80% Motor Pressure Size Required Pipe Size Inlet Orifice Size Model MBtu/hr Eff. (“w.c.”) (in.) (“w.c) (in.) (“w.c.) Size (in.) (in.)
- Page 7 Q Series On-Off Standard Dimensions 12X R ØN ØM 60° ØK 30° 45° 90° Accompanying dimensions are for layout purposes only. Burner Model Length in inches Overall burner length 22 7/8 25 5/8 Width in inches Center line to left side 12 1/2 15 5/16 Center line to right side...
- Page 8 Q Series Full Modulation Standard Dimensions 12X R ØN ØM 60° ØK 30° 45° 90° Accompanying dimensions are for layout purposes only. Burner Model Length in inches Overall burner length 22 7/8 25 5/8 Width in inches Center line to left side 12 1/2 15 5/16 Center line to right side...
- Page 9 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 &...
- Page 10 Q Series Spare Parts List Continued GAS TRAIN PART DESCRIPTION - GAS TRAIN COMPONENTS 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”...
- Page 11 SPRING PIN ELECTRODE ORIFICE PLATE LOCK WASHER STANDOFF BAFFLE WELDMENT LOCK WASHER SCREW FLAME ROD Firing Head Assembly w/Flame Rod FIGURE 0-1. ELECTRODE SPRING PIN LOCK WASHER ORIFICE PLATE LOCK WASHER STANDOFF BAFFLE WELDMENT UV SCANNER LOCK WASHER SCREW SCREW Firing Head Assembly w/UV Scanner FIGURE 0-2.
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Page 13: Table Of Contents
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 2.6 — Packaging Plastic Refractory Around Oven (If Dry Oven is Supplied) 750-370 ProFire Q Series Manual... - Page 14 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 4-2 750-370 ProFire Q Series Manual...
- Page 15 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...
- Page 16 Troubleshooting 6-1 CHAPTER 6 6.1 — Awareness 6-1 6.2 — Emergency Shutdown 6-2 6.3 — Problem/Possible Causes 6-3 STARTUP/SERVICE REPORT WARRANTY POLICY 750-370 ProFire Q Series Manual...
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Page 17: Introduction
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. 750-370 ProFire Q Series Manual... -
Page 18: Operating Controls
Full speed modulation with Pulse Width Modulation signal input rated voltage 24VDC, 115VAC DC Pulse Width Modulation Blower speed controlled by UGB board for LHL burners or LMV37 (See LMV37 manual for details) for modulating burners. 750-370 ProFire Q Series Manual... -
Page 19: Firing Head
Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating sequence. 750-370 ProFire Q Series Manual... -
Page 20: Main Gas Train Components
FIGURE 1-2. VARIABLE AIR/GAS RATIO CONTROL PRESSURE W/SOLENOID LEAK HIGH VALVE SWITCH VALVE TEST REGULATOR VALVE PRESSURE SWITCH SHUTOFF SHUTOFF VALVE VALVE LEAK TEST PORTS 750-00515-000 Main Gas Train for Low-High-Low (Q6-037 to Q8-250) FIGURE 1-3. 750-370 ProFire Q Series Manual... -
Page 21: Operation
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. 750-370 ProFire Q Series Manual... - Page 22 Introduction 750-370 ProFire Q Series Manual...
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Page 23: Installation
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. 750-370 ProFire Q Series Manual... -
Page 24: Combustion Chamber Recommendations
FLOOR STANDARD FIREBRICK BLOCK INSULATION 750-00511-000 Combustion Combustion Chamber Chamber Burner (in.) (in.) (in.) Min. Width Min. Length Size (in.) (in.) Q6-037 Q6-055 Q6-075 Q6-100 Q6-130 Q6-150 Q8-175 Q8-200 Q8-250 Combustion Chamber Dimensions FIGURE 2-1. 750-370 ProFire Q Series Manual... -
Page 25: Installation
(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. 750-370 ProFire Q Series Manual... -
Page 26: Support Bracket Installation
SIZE "A" "B" "C" "D" "E" 1/4-20 SIZED TO 3/8-16 FIT BOILER "A" "B" 4.00 4X "C" X "D" LG STUDS 45° 45° 90° "E" 1.44 SECTION A-A 710-00775-000 Q Series Refractory Dimensions FIGURE 2-4. 750-370 ProFire Q Series Manual... -
Page 27: Gas Piping
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. 750-370 ProFire Q Series Manual... - Page 28 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. 750-370 ProFire Q Series Manual...
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Page 29: Operation
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. 750-370 ProFire Q Series Manual... -
Page 30: Burner 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 750-370 ProFire Q Series Manual... -
Page 31: Test Equipment
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. 750-370 ProFire Q Series Manual... -
Page 32: Automatic Shutdown
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. 750-370 ProFire Q Series Manual... -
Page 33: Startup And Operating
“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. 750-370 ProFire Q Series Manual... -
Page 34: Burners Designed For On-Off Operation
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. 750-370 ProFire Q Series Manual... -
Page 35: Burners Designed For Modulation Operation
Use the ¿ and + buttons to advance until the phase screen is displayed (PHXX). Turn the burner switch on and burner will advance to phase 36 and purge. After purge is complete, the burner will modulate to its light-off point (P0). 750-370 ProFire Q Series Manual... - Page 36 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. 750-370 ProFire Q Series Manual...
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Page 37: Normal Operation
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. 750-370 ProFire Q Series Manual... -
Page 38: Shutdown
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. 3-10 750-370 ProFire Q Series Manual... -
Page 39: Adjustments
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. 750-370 ProFire Q Series Manual... -
Page 40: Gas Adjustments
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. 750-370 ProFire Q Series Manual... -
Page 41: Direct Spark Ignition Flame Adjustment
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. 750-370 ProFire Q Series Manual... -
Page 42: Parallel Positioning Adjustment
Warning Keep fingers away from the air intake below the damper. The damper is actuated with sufficient force to cause severe injury. 750-370 ProFire Q Series Manual... -
Page 43: Maintenance
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. 750-370 ProFire Q Series Manual... -
Page 44: Programming Control
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. 750-370 ProFire Q Series Manual... -
Page 45: Ignition Electrode & Flame Rod
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. 750-370 ProFire Q Series Manual... -
Page 46: Burner Mounting Inspection
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. 750-370 ProFire Q Series Manual... -
Page 47: Extended Shutdown
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. 750-370 ProFire Q Series Manual... - Page 48 Maintenance 750-370 ProFire Q Series Manual...
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Page 49: Chapter 6 Troubleshooting
Following a set routine may help to detect obvious conditions, often ones that are relatively simple to correct. 750-370 ProFire Q Series Manual... -
Page 50: Emergency Shutdown
“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. 750-370 ProFire Q Series Manual... -
Page 51: Problem/Possible Causes
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. 750-370 ProFire Q Series Manual... - Page 52 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. 750-370 ProFire Q Series Manual...
- Page 53 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_______________...
- Page 54 750-370 ProFire Q Series Manual...
- Page 55 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 750-370 ProFire Q Series Manual...
- Page 56 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. 750-370 ProFire Q Series Manual...
- Page 58 Web Address: http://www.cleaverbrooks.com...
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