CleaverBrooks ProFire D Series Installation, Operation, Service, And Parts Manual
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CleaverBrooks ProFire D Series Installation, Operation, Service, And Parts Manual

CleaverBrooks ProFire D Series Installation, Operation, Service, And Parts Manual

Gas/oil/dual fuel
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ProFire D/LND
Burners
Gas/Oil/Dual Fuel
Installation, Operation, Service, and Parts
Manual Part No. 750-204
07/2019

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Summary of Contents for CleaverBrooks ProFire D Series

  • Page 1 Table Of Contents ProFire D/LND Burners Gas/Oil/Dual Fuel Installation, Operation, Service, and Parts Manual Part No. 750-204 07/2019...
  • Page 3 PROFIRE D/LND Installation, Operation, and Service Manual Manual Number: 750-204 Release Date: July 2019...
  • 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 Cleaver-Brooks. Cleaver-Brooks 351 21st Street Monroe, WI 53566 608-325-3141 www.cleaverbrooks.com...
  • Page 5 PREFACE 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.
  • Page 6 ment shall be connected to flues having sufficient draft at all times to assure safe and proper opera- tion of the burner. The D Series burners are designed to burn either gas or light oil No. 1 or 2 as defined by ASTM D396-1978 specifications, and heavy oils.
  • Page 7 Burner Size Max. Burner Oil Input U.S.G.P.H. 60hz 50hz 42 (S or P) 54 (S or P) 63 (S or P) 84 (S or P) 105 (S or P) 145 (S or P) 175 (S or P) 210 (S or P) 252 (S or P) 300 (S or P) 315 (P)

  • Page 9: Table Of Contents

    Profire D/LND Table of Contents Introduction 1-1 CHAPTER 1 1.1 — Overview 1-1 1.2 — Description 1-1 1.3 — Operating Controls 1-2 1.4 — Flame Safeguard Controls 1-2 1.5 — Combustion Air Handling System 1-3 1.6 — Firing Rate Controls 1-3 1.7 —...
  • Page 10 2.2 — Combustion Chamber Construction 2-1 2.3 — Installation 2-4 2.4 — Packing Plastic Refractory Around Oven 2-5 2.5 — Separate Compressor Module 2-5 2.6 — Typical Oil Supply Loop 2-6 2.7 — Oil Circulating Loop Operation 2-7 2.8 — Circulating Oil Pump 2-8 2.9 —...
  • Page 11 3.4 — Startup Sequence 3-4 3.5 — Automatic Shutdown 3-5 3.6 — Manual Shutdown 3-5 3.7 — Safety Shutdown 3-5 3.8 — Startup and Operating 3-6 3.8.1 — Gas Burners 3-6 3.8.2 — Oil Burners 3-6 3.9 — Normal Operation 3-7 3.10 —...
  • Page 12 4.5 — Oil System 4-5 4.5.1 — Oil Metering System 4-5 4.5.2 — Atomizing Air Pressure 4-6 4.5.3 — Atomizing Air Proving Switch 4-6 4.5.4 — Low Oil Pressure Switch 4-6 4.5.5 — High Oil Temperature Switch 4-6 4.5.6 — Nozzle Line Heater 4-7 4.6 —...
  • Page 13 5.11 — Fuel Oil System 5-7 5.11.1 — Fuel Oil Circulating Pump 5-7 5.11.2 — Air-Oil Metering Pump 5-7 5.11.3 — Primary Air Pump or Compressor 5-8 5.11.4 — Air Cleaner 5-8 5.11.5 — Air-Oil Tank 5-8 5.11.6 — Oil Level Sight Gauge 5-8 5.11.7 —...
  • Page 14 Flue Gas Recirculation 8-1 CHAPTER 8 8.1 — LN Model Designations, Sizes, and Inputs 8-1 8.2 — Description 8-3 8.3 — FGR Shutoff Valve 8-4 8.4 — FGR Control Valve 8-5 8.5 — Air/FGR Damper Assembly 8-5 8.6 — Blast Tube Temperature Interlock (optional) 8-7 8.7 —...
  • Page 15 9.4.16 — Drawer Assembly D378 - 420 9-34 9.4.17 — Firing Head Assembly D42 - 420 9-36 9.4.18 — Oil Air Tank DL, DM42 - 145 9-38 9.4.19 — Oil Heater D42 -420 9-39 9.4.20 — Oil Metering Assembly DL, DLG, DM, DMG42 - 145 9-41 9.4.21 —...
  • Page 16 viii 750-204 Profire D/LND...

  • Page 17: Introduction

    Introduction CHAPTER 1 1.1 — Overview Profire D/Series burners are assembled, wired, and tested at the factory. They are listed by the Underwriters Lab- oratory, CSD-1, NFPA-85, I.R.I., F.M., including the National electrical Code (NEC) and associated insurance underwriters. Where applicable, the Canadian Gas Association (CGA) B149 and Canadian Standards Association (CSA) B140 codes shall prevail.

  • Page 18: Operating Controls

    Introduction 1.3 — Operating Controls The control panel contains a flame safeguard programming control, motor starters, relays, time delays, and ter- minal strips mounted internally on a panel subbase. Lights, switches, potentiometers, a control circuit breaker, and flame safeguard displays are mounted externally on the panel as indicated: Component Details On-Off Burner Switch...

  • Page 19: Combustion Air Handling System

    1.5 — Combustion Air Handling System 1.5 — Combustion Air Handling System The combustion air handling system consists of three major components: Component Details Damper Assembly A rotary damper regulates the combustion air volume and is positioned by a modulating motor. The damper is normally almost closed in the low fire position and opens as the burner drives toward a high fire position.

  • Page 20: Firing Head

    Introduction metering pump, and/or gas volume butterfly valve are controlled through variable rate rod and lever linkages. The modulating motor rotates 90º from low to high position. Flow rate through each component is adjusted by posi- tioning the control rods on the levers and the angular position of levers on shafts. The lever on the modulating motor shafts actuate the high fire position proving switch.

  • Page 21: Oil System Air Atomizing

    1.8 — Oil System Air Atomizing FIGURE 1-3. Dual Gas Manifold 1.8 — Oil System Air Atomizing D Model burners use compressed air for atomization. Atomizing air is independent of combustion air. Either of two air/oil systems are used, depending on burner size and fuel. ONe system uses an integral air compressor/oil metering unit mounted on the burner and is driven by a separate motor.

  • Page 22: Burner Mounted Trim Heater

    Introduction The nozzle body has inlet ports for air and oil lines. Metered fuel oil enters the nozzle body and flows through a tube to the swirler. Oil is forced from the core of the swirler to the side ports where it meets with atomizing air. Atomizing air enters and passes through the nozzle body to grooves in the swirler, where it mixes with fuel oil.

  • Page 23: Air Compressor

    1.8 — Oil System Air Atomizing Integral Air/Oil Unit FIGURE 1-5. 1.8.9 — Air Compressor Air is drawn into the vane-type, rotary compressor section of the air/oil unit through an air cleaner. The com- pressed air flows to an air-lube oil tank which serves the multiple purpose of lube oil mist recovery, lube oil sump, and air storage.
  • Page 24 Introduction Air Compressor Module. Air is supplied by a positive displacement rotary vane compressor. This provides a constant volume of atomizing air regardless of pressure. The compressor module includes motor, air-oil reser- voir tank, air filter, and lube oil cooling coil. Air enters the compressor through the filter. The air flows from the compressor into the air-oil separating and reservoir tank.
  • Page 25 1.8 — Oil System Air Atomizing Fuel Oil Metering System (Used With Separate Compressor) FIGURE 1-7. Integral Compressor Oil-Air Metering System FIGURE 1-8. 750-204 Profire D/LND...

  • Page 26: Gas System

    Introduction FIGURE 1-9. Compressor Module and Burner Oil Flow 1.9 — Gas System Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold. Fir- ing rate is determined by the size and number of ports, by manifold pressure and by combustion zone pressure. The firing rate is regulated by a rotary, butterfly type throttling valve at the manifold inlet.

  • Page 27: Main Gas Train Components

    1.9 — Gas System 1.9.1 — Main Gas Train Components Depending on 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 linkage from the modulating motor and controls the rate of flow of gas.

  • Page 28: Pilot Gas Train Components

    Introduction 1.9.2 — Pilot Gas Train Components Component Description Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to the pilot. It closes after main flame is established. Gas Pressure Regulator Reduces gas pressure to that required by the pilot. Gas Pilot Shutoff Cock For manually closing the pilot gas supply.

  • Page 29: Installation

    Installation CHAPTER 2 2.1 — Application Electrical power available is usually 208 volt, 3-phase, 60 cycle, 230/460 volt, 3-phase, 60 cycle or 380 volt, 3-phase, 50 cycle. The control circuit is 115 volt, single phase, 60 cycle or 115 volt, single phase, 50 cycle. Refer to the electrical schematic diagram shipped with the burner.
  • Page 30 Installation FIGURE 2-1. Recommended Scotch Marine Chamber Dimensions 750-204 Profire D/LND...
  • Page 31 2.2 — Combustion Chamber Construction Recommended Firebox & Watertube Boiler Chamber Dimensions FIGURE 2-2. 750-204 Profire D/LND...

  • Page 32: Installation

    Installation 2.3 — Installation Locate the burner properly. The burner is designed for operation with the blast tube level. Do not tilt the burner up or excessively downward. Installation of the refractory oven or combustion cone, shipped with the burner, is shown in Figures 2-3 and 2-4.

  • Page 33: Packing Plastic Refractory Around Oven

    2.4 — Packing Plastic Refractory Around Oven Caution It is important that you provide support for the housing when in the open position to prevent damage to the hinges and subsequent components. FIGURE 2-4. Scotch Marine Burner Mounting Details 2.4 — Packing Plastic Refractory Around Oven The area between the outside circumference of the dry oven 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.

  • Page 34: Typical Oil Supply Loop

    Installation the blast tube, but piping to the compressor and tank is essentially similar. Copper tubing for the installation is not supplied with the burner. Separate Compressor Module FIGURE 2-5. 2.6 — Typical Oil Supply Loop Refer to Figure 2-6. Continuous oil circulation must be supplied to the burner at a rate of 50% greater than the high fire burning rate.

  • Page 35: Oil Circulating Loop Operation

    2.7 — Oil Circulating Loop Operation Typical Oil Supply Loop FIGURE 2-6. 2.7 — Oil Circulating Loop Operation No. 2 Oil: Refer to Figures 2-7 to 2-9 at the end of this chapter. No. 4 & 5 Oil: Refer to Figures 2-10 to 2-12 at the end of this chapter. See Section 2.9 for heater operation. No.

  • Page 36: Circulating Oil Pump

    Installation An oil circulating pump provides continuous oil circulation to the circulation loop. A back pressure valve holds 10 to 15 PSI on the loop system. With the oil supply line connected only to the oil metering pump inlet, all oil must pass through the pump.

  • Page 37: Gas Piping

    2.12 — Gas Piping blow out the pipe line, removing all dirt, pipe scale, and sediment. This type of valve is actuated by the system pressure which enters the body beneath the main valve. Valve loading is provided by a spring that can be adjusted to the desired set pressure.
  • Page 38 Installation Check: • Electrical terminals in the control panel and on all electrical components. • Pipe fittings and unions. • Tubing connections. • Nuts, bolts, screws. Before operating pumps, metering heads, and compressors, make certain that reservoirs are properly filled with the specific lubricant.
  • Page 39 2.13 — Installation Checklist Recommended Pipe Size FIGURE 2-7. 2-11 750-204 Profire D/LND...
  • Page 40 Installation FIGURE 2-8. Recommended Pipe Size 2-12 750-204 Profire D/LND...
  • Page 41 2.13 — Installation Checklist BACK PRESSURE VALVE SET AT 10-15 PSI 2-WAY VALVE ON BURNER TO DRAWER ASSEMBLY 3-WAY VALVE RELIEF ON BURNER VALVE NEW YORK CITY ONLY LOW OIL PRESSURE SWITCH CHECK PRESSURE VALVE REQUIRED IF PUMP DOES NOT GAUGE &...
  • Page 42 Installation FIGURE 2-10. Recommended Pipe Size 2-14 750-204 Profire D/LND...
  • Page 43 2.13 — Installation Checklist FIGURE 2-11. Recommended Pipe Size 2-15 750-204 Profire D/LND...
  • Page 44 Installation FIGURE 2-12. Recommended Pipe Size 2-16 750-204 Profire D/LND...
  • Page 45 2.13 — Installation Checklist FIGURE 2-13. Recommended Pipe Size 2-17 750-204 Profire D/LND...
  • Page 46 Installation Recommended Pipe Size FIGURE 2-14. 2-18 750-204 Profire D/LND...
  • Page 47 2.13 — Installation Checklist Multiple Boilers Installation-Heavy Oil FIGURE 2-15. 2-19 750-204 Profire D/LND...
  • Page 48 Installation FIGURE 2-16. Typical UL Gas Piping FIGURE 2-17. Typical UL Gas Piping 2-20 750-204 Profire D/LND...
  • Page 49 2.13 — Installation Checklist FIGURE 2-18. Typical UL Gas Piping Typical UL Gas Piping FIGURE 2-19. 2-21 750-204 Profire D/LND...
  • Page 50 Installation 2-22 750-204 Profire D/LND...

  • Page 51: Operation

    Operation CHAPTER 3 3.1 — Preparations for Starting When the installation is complete and all electrical, fuel, water and vent stack connections are made, make cer- tain these connections are tight. The operator should become familiar with the burner, boiler controls, and com- ponents.

  • Page 52: Oil Flow

    Operation Component Description Boiler Check the boiler water level. Be sure all boiler valves are installed correctly and posi- tioned properly. Set the high limit control slightly above the desired temperature. Set modulating controls at the desired temperature or pressure. Firing Preparations for Prior to initial firing, oil flow pressure and temperature should be verified.

  • Page 53: Air-Oil Tank (Lube Oil)

    3.2 — Electrical Interference Test heater should be adjusted to give the designed operating temperature. Where the burning characteristics of the fuel are unknown, the following may be considered as typical: No. 4 80º - 125º F No. 5L 115º - 160º F No.

  • Page 54: Gas Pilot Flame Adjustment

    Operation Close the pilot line manual gas valve (if used). Start the burner and at the time of the pilot trial, with just the electrical ignition system energized, the flame relay should not pull in. Upon completion of a successful test, disconnect the power supply. Reconnect the oil safety shutoff valve and turn on the manual pilot gas valve.

  • Page 55: Automatic Shutdown

    3.5 — Automatic Shutdown Refer to the manufacturer’s literature on programming controls and burner wiring diagrams for detailed informa- tion. Begin starting sequence, with burner switch off, and with all manual valves closed. Switch main power on. When firing oil, open the manual oil valves. When firing on gas, open the main manual gas valve.

  • Page 56: Startup And Operating

    Operation 3.8 — Startup and Operating 3.8.1 — Gas Burners Close the main and pilot gas cocks. Make sure the “ON-OFF” switch is in the “OFF” position and the fuel selector switch is on “GAS.” Actuate the manual reset button of the flame safeguard control to close the safety switch contacts. Set the “MANUAL-AUTO”...

  • Page 57: Normal Operation

    3.9 — Normal Operation Observe the primary atomizing air pressure gauge on the air/oil tank. The gauge reading should be approxi- mately 10 psi during pre-purge. When the pilot flame is proven, the programmer will proceed to the main flame position. Allow the burner to operate in low fire, to warm the boiler before moving to high fire.
  • Page 58 Operation during the pre-purge 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 for additional information.

  • Page 59: Adjustments

    Adjustments CHAPTER 4 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 instal- lation 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 mis-adjust- ments occurred during shipping and installation.

  • Page 60: Smoke Measurement

    Adjustments 4.2.2 — Smoke Measurement Smoke measurements can be made using a variety of different methods. The standards will vary somewhat according to the equipment used, and instructions accompanying the instrument should be followed. Smoky combustion can result from: • improper air delivery •...

  • Page 61: Gas System

    4.4 — Gas System 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 fur- nace pressure while running at full input. Refer to the nameplate inside the control panel for gas pressure require- ments at the train inlet and manifold.

  • Page 62: High Gas Pressure Switch

    Adjustments 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.

  • Page 63: Secondary Valve Adjustment: Dual Manifold

    4.5 — Oil System Gas Primary and Secondary Valve Arrangement: D 378-420 FIGURE 4-1. 4.4.9 — Secondary Valve Adjustment: Dual Manifold Each zone is controlled by a butterfly valve linked to a 14 point adjustment cam. The primary large butterfly valve controls the main gas orifices and the secondary small butterfly valve controls the pre-mix gas spuds.

  • Page 64: Atomizing Air Pressure

    Adjustments That all oil valves between the burner and the tank are open. That the suction line is not airbound. That the low fire setting has not been disturbed. That there is pressure at the integral metering unit, but not to exceed 15 psi (20 psi on a separate metering unit).

  • Page 65: Nozzle Line Heater

    4.6 — Linkage: Modulating Motor 4.5.6 — Nozzle Line Heater NOTE: Be sure the manifold is filled with oil prior to startup. Remove the cover that encloses the thermostat and interlock switch. The pointer controls the thermostat set- ting. The knurled knob controls the cold oil interlock switch. The thermostat pointer should be set at position 6 and then raised or lowered as required.
  • Page 66 Adjustments Low Fire Position FIGURE 4-3. FIGURE 4-4. High Fire Position The modulating motor will be stopped at the end of its stroke by an internal limit switch. Combustion gas analy- sis indicates the air to fuel ratio and the degree of complete combustion. The closer the rod comes to parallel 750-204 Profire D/LND...

  • Page 67: Cam Trim Adjustment

    4.7 — Cam Trim Adjustment with the lever, the slower the rod moves. The angles of the driven levers on the jackshaft can be adjusted to vary the rate of change. The closer the rod to the hub of the lever, the less distance it will travel. Increasing the lever length on the damper, metering unit and valve(s) decreases flow rate.
  • Page 68 Adjustments rate. Driving and driven levers are approximately parallel, but the angles can be adjusted to vary the rate of change. The most rapid rod travel occurs when the lever is perpendicular to the rod. The closer the rod comes to being parallel with the lever, the slower the rod moves.
  • Page 69 4.8 — Firing Rate Controls FIGURE 4-7. Motor Rotations 4-11 750-204 Profire D/LND...
  • Page 70 Adjustments 4-12 750-204 Profire D/LND...

  • Page 71: Maintenance

    Maintenance CHAPTER 5 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.

  • Page 72: Programming Control

    Maintenance 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. 5.2.1 —...
  • Page 73 5.4 — Firing Head Inspection The oil nozzle should be inspected periodically depending on the grade of oil burned and the cleanliness of the environment. FIGURE 5-2. Firing Head Assembly: Dual Manifold Firing Head Assembly: D378 & 420 FIGURE 5-3. 750-204 Profire D/LND...

  • Page 74: Pilot And Ignition Electrode

    Maintenance 5.5 — Pilot and Ignition Electrode The ignition transformer requires little attention other than making sure the ignition wire is firmly attached to the transformer and the electrode. Ignition Pilot Electrode Setting FIGURE 5-4. 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.
  • Page 75 5.7 — Oil Nozzle Hold the nozzle body in a vise or use two wrenches, one on the body and one on the tip. Disassemble the nozzle tip. Carefully clean all parts in solvent and reassemble the nozzle. To insure proper atomizing, the tip must be screwed in tightly with the swirler seating spring pressing the swirler tight against the nozzle tip.

  • Page 76: Diffuser

    Maintenance Caution Do not attempt to use a wire or a sharp metal tool to clean the nozzle orifice as this will distort the fine orifice and ruin the nozzle. Use a sharp pointed piece of soft wood. 5.8 — Diffuser The diffuser is factory set and does not require attention under normal operating conditions.

  • Page 77: Fuel Oil System

    5.11 — Fuel Oil System 5.11 — Fuel Oil System 5.11.1 — Fuel Oil Circulating Pump Failure or the circulating pump to deliver sufficient oil may be due to one of the following conditions: Insufficient fuel oil in the storage tank. Suction line or check valve clogged.

  • Page 78: Primary Air Pump Or Compressor

    Maintenance 5.11.3 — Primary Air Pump or Compressor The air compressor itself requires little maintenance, however, its life is dependent upon sufficient clean, cool lubricating oil. The oil level in the air-oil tank must be checked regularly. Lack of oil will damage the compressor. Disassembly or field repairs to the air compressor are not recommended.

  • Page 79: Nozzle Line Heater

    5.12 — Gas System 5.11.8 — Nozzle Line Heater Nozzle line heaters damaged by water accumulation do not qualify for warranty or exchange service. Failure to prevent water accumulation inside the heater manifold constitutes improper care. Completely drain the heater manifold periodically. This should be part of the preventive maintenance program. maintenance consists primarily of removing the heating element from the manifold and scraping any accumula- tion of carbonized oil or sludge deposits from the heat exchange surfaces.

  • Page 80: Electrical System

    Maintenance Test for gas leaks and check the valve action several times to ensure proper operation before attempting to relight the burner. 5.13 — Electrical System Because of the many types of flame safeguard systems applicable to this equipment, complete descriptions of all D Series burner electrical systems are beyond the scope of this manual.

  • Page 81: Maintenance Flow Chart Recommended Test Schedule

    5.15 — Maintenance Flow Chart Recommended Test Schedule 5.15 — Maintenance Flow Chart Recommended Test Schedule Item Service By Remarks DAILY Gauges, Monitors, Indicators Operator Make visual inspection and record readings in log. Instrument and Equipment Settings Operator Make visual check against recommended specifications. Low Water, Fuel Cutoff, Alarms Operator Refer to instructions.
  • Page 82 Maintenance 5-12 750-204 Profire D/LND...

  • Page 83: Troubleshooting

    Troubleshooting CHAPTER 6 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.

  • Page 84: Emergency Shutdown

    Troubleshooting 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 possi- bly eliminate overlooking an obvious condition, often one that is relatively simple to correct. If an obvious condition is not apparent, check each continuity of each circuit with a voltmeter or test lamp.

  • Page 85: Troubleshooting

    6.3 — Troubleshooting 6.3 — Troubleshooting Problem Solution Burner Does Not Start 1. No voltage at 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.
  • Page 86 Troubleshooting Problem Solution Pilot Flame, But No Main Flame 1. Insufficient pilot flame. 2. Gas fired unit: a. Manual gas cock closed. b. Main gas valve inoperative. c. Gas pressure regulator inoperative. 3. Limit circuit not completed, no voltage at end of limit circuit program relay terminal.
  • Page 87 6.3 — Troubleshooting Problem Solution 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.
  • Page 88 Troubleshooting 750-204 Profire D/LND...

  • Page 89: Accessories

    Accessories CHAPTER 7 7.1 — Overview The D Series burners are available with a wide selection of accessories. This section will cover some of the most popular accessories. 7.2 — Steam Atomizing System Steam Atomizing System FIGURE 7-1. 750-204 Profire D/LND...

  • Page 90: Air Purge System (Optional)

    Accessories The steam atomizing line is shipped loose and must be piped and wired to the burner as shown in the diagram below. Refer to the wiring diagram for the electrical connection. The air compressor is used for cold oil startup. Start the boiler with the air atomizing system first.
  • Page 91 7.4 — Plant Air System Adjust the air pressure with the regulator and fine tune with the needle valve to have 10-15 psi on low fire. Refer to Chapter 4 to setup the burner. FROM SUPPLY WIRE TO FLAME FLOW SAFEGUARD BLOWER MOTOR TERMINAL Plant Air System/Top Loaded with Air...
  • Page 92 Accessories FROM SUPPLY OIL PRESSURE DOWN STREAM OF OIL METERING VALVE/NOZZLE PRESSURE TO TOP LOAD AIR PRESSURE REGULATING VALVE WIRE TO FLAME SAFEGUARD BLOWER FLOW MOTOR TERMINAL NOTE: 1 - AIR PRESSURE REGULATOR SHOULD HAVE TRIM KIT TO ALLOW OIL OVER REGULATOR FIGURE 7-4.

  • Page 93: Flue Gas Recirculation

    Flue Gas Recirculation CHAPTER 8 8.1 — LN Model Designations, Sizes, and Inputs Model designations are based on the type of fuel(s) to be fired and the amount of furnace pressure to overcome. Burner size is based on firing rate (maximum input in Btu/hr.). Models Standard Fuel-Air Atomization LNDG...
  • Page 94 Flue Gas Recirculation Burner Size Max. Burner Gas Input MBTU/hr. <30 ppm <20 ppm 42 P 3,360 54 P 4,200 3,360 63 P 5,250 4,200 84 S 6,300 5,250 84 P 7,350 6,300 105 P 8,400 7,350 145 S 10,500 8,400 145 P 12,600...

  • Page 95: Description

    8.2 — Description Burner Size Max. Burner Oil Input U.S.G.P.H. <30 ppm <20 ppm 42 P 54 P 63 P 84 S 84 P 105 P 145 S 145 P 175 P 210 P 252 P 300 P 315 P 336 P 378 P 420 P...

  • Page 96: Fgr Shutoff Valve

    Flue Gas Recirculation FIGURE 8-1. General Layout of the Burner 8.3 — FGR Shutoff Valve The FGR shutoff valve is located as close to the stack as possible. A modutrol motor with a 90º stroke opens and closes the FGR shutoff valve in 15 seconds.

  • Page 97: Fgr Control Valve

    8.4 — FGR Control Valve 8.4 — FGR Control Valve The FGR control valve is mounted to an FGR damper on the burner. A burner mounted modutrol motor with linkage connections coordi- nates the air, fuel, and NOx control devices to provide proper fuel/air/NOx ratios through the fir- ing range.
  • Page 98 Flue Gas Recirculation FIGURE 8-4. FGR Piping and Valve Sizes 750-204 Profire D/LND...

  • Page 99: Blast Tube Temperature Interlock (Optional)

    8.6 — Blast Tube Temperature Interlock (optional) 8.6 — Blast Tube Temperature Interlock (optional) A blast tube temperature interlock device monitors air temperature in the blast tube area of the burner. If the blast tube temperature rises above 200º F maximum. An external scanner is used on the low emission burners. 8.7 —...
  • Page 100 Flue Gas Recirculation FIGURE 8-6. 20 PPM Head Assembly 750-204 Profire D/LND...

  • Page 101: Parts Lists And Drawings

    Parts Lists and Drawings CHAPTER 9 9.1 — Instructions When ordering repair parts, please include: • Part Number • Burner Serial Number • Model • Size • Voltage This information can be obtained from the burner nameplate and the data label (voltage) on the panel door. When ordering fan wheels, give the overall diameter, width, bore manufacturer, and motor HP.

  • Page 102: Return Goods Procedures (Credit Or Replacement Parts)

    Parts Lists and Drawings Ground shipments to Wisconsin and bordering states will be shipped the same day upon request. All parts orders and exchange parts must be sent to: Cleaver-Brooks 351 21st Street Monroe, Wisconsin 53566 Plant Phone: (608) 325-3141 Fax: (608) 325-4379 Parts Direct: (608) 325-5003 Fax: (608) 329-3190...
  • Page 103 9.3 — Return Goods Procedures (Credit or Replacement Parts) Remove the motor from the unit and take the motor to a Manufacturer Authorized Service Station. The Service Station will determine the warranty status be installation date of the unit, and date of failure, along with the age of the motor, determined by the code date.

  • Page 104: Parts Lists And Drawings

    Parts Lists and Drawings 9.4 — Parts Lists and Drawings 9.4.2 — Blast Tube Assembly D42 - 336 750-204 Profire D/LND...
  • Page 105 9.4 — Parts Lists and Drawings Blast Tube Assembly Quantity Item Part No. Description 8-1029 Bracket, 23” Support, Standard Panel 8-1275 Bracket, 28” Support, Standard Panel 817-829 Switch, Pressure, Air Oil, 4-12 psi 40-377 Housing Assembly, Firing Head 40-378 Housing Assembly, Firing Head 40-400 Housing Assembly, Firing Head 40-381...

  • Page 106: Blast Tube Assembly D378

    Parts Lists and Drawings 9.4.2 — Blast Tube Assembly D378 - 420 750-204 Profire D/LND...
  • Page 107 9.4 — Parts Lists and Drawings Blast Tube Assembly Quantity Item Part No. Description 8-1275 Bracket, 28” Support, Standard Panel Switch, Pressure Air-Oil, 4-12 psi 40-380 Housing Assembly, Firing Head 40-410 Housing Assembly, Firing Head 40-402 Housing Assembly, Firing Head 8-1018 Bracket 836-301...

  • Page 108: Blower Housing Assembly D42

    Parts Lists and Drawings 9.4.3 — Blower Housing Assembly D42 - 175 750-204 Profire D/LND...
  • Page 109 9.4 — Parts Lists and Drawings Blower Housing Assemblies Quantity Item Part No. Description 894-1200 Motor, 3 HP S&P 894-1237 Motor, 5 HP S&P 894-1240 Motor, 7.5 HP 894-1209 Motor, 10 HP 894-1245 Motor, 15 HP S&P 894-1247 Motor, 20 HP S&P 29-834 Flange, Motor Mounting...

  • Page 110: Blower Housing Assembly D210

    Parts Lists and Drawings 9.4.4 — Blower Housing Assembly D210 - 336 9-10 750-204 Profire D/LND...
  • Page 111 9.4 — Parts Lists and Drawings Blower Housing Assemblies Quantity Item Part No. Description 894-1249 Motor, 20 HP 894-1251 Motor, 25 HP 894-1255 Motor, 40 HP S&P 894-1351 Motor, 60 HP 515-16 Seal 39-452 Shroud Assembly, Air Hood 85-812 Support, Motor and Air Damper 85-813 Support, Motor and Air Damper Spacer (varies)

  • Page 112: Blower Housing Assembly D378

    Parts Lists and Drawings 9.4.5 — Blower Housing Assembly D378 - 420 9-12 750-204 Profire D/LND...
  • Page 113 9.4 — Parts Lists and Drawings Blower Housing Assemblies Quantity Item Part No. Description 894-1368 Blower Motor 515-16 Seal Plate 85-813 Shroud Assembly, Air Hood 85-891 Support, Motor and Air Damper Spacer (varies) 192-327 Impeller Assembly 869-185 Nut, Hex Lock 1-3/8” 12 UNF 152-17 Pad, Blower Motor Mounting 836-336...

  • Page 114: Compressor Set D42

    Parts Lists and Drawings 9.4.6 — Compressor Set D42 - 145 9-14 750-204 Profire D/LND...
  • Page 115 9.4 — Parts Lists and Drawings Separate Compressor Modules Quantity Item Part No. Description 940-1205 Valve, Check 3/4” Horizontal 941-562 Valve, Shutoff 3/4” NPT (Butterball) 941-584 Valve, Shutoff 1-1/4” NPT (Butterball) 923-112 Filter, Air 894-1291 Motor, 3 HP 894-1302 Motor, 5 HP 848-499 Box, Electrical W/Cover 29-841...

  • Page 116: Compressor Set D175

    Parts Lists and Drawings 9.4.7 — Compressor Set D175 - 336 9-16 750-204 Profire D/LND...
  • Page 117 9.4 — Parts Lists and Drawings Separate Compressor Modules Quantity Item Part No. Description 940-1205 Valve, Check 3/4” Horizontal 941-584 Valve, Shutoff 1-1/4” NPT (Butterball) 923-112 Filter, Air 894-1302 Motor, 5 HP 894-1309 Motor, 7.5 HP 848-499 Box, Electrical W/Cover 4” X 4” 29-841 Flange, Compressor Mounting 505-153...

  • Page 118: Compressor Set D378

    Parts Lists and Drawings 9.4.8 — Compressor Set D378 - 420 9-18 750-204 Profire D/LND...
  • Page 119 9.4 — Parts Lists and Drawings Compressor Set Assemblies Quantity Item Part No. Description 35-440 Radiator Guard Assembly 17-234 Radiator Assembly 848-514 Electrical Junction Box 39-446 Air Flow Duct Assembly 35-439 Belt Guard Weldment 951-174 Fan Blade 74-516 Fan Mounting Shaft 809-223 V-Belt 810-73...

  • Page 120: Control Package, Fireye

    Parts Lists and Drawings 9.4.9 — Control Package, Fireye 9-20 750-204 Profire D/LND...
  • Page 121 9.4 — Parts Lists and Drawings Fireye Control Package Quantity Item Part No. Description 833-1340 Module, Display W/Controller Mounting Cable 832-915 Program Module, EP160, 60 Sec. Pre-Purge 832-916 Program Module, EP360, 60 Sec. Pre-Purge 832-917 Program Module, EP390, 90 Sec. Pre-Purge 832-914 Amplifier, Signal Autochecking (Infrared) 832-918...

  • Page 122: Control Package, Honeywell

    Parts Lists and Drawings 9.4.10 — Control Package, Honeywell 9-22 750-204 Profire D/LND...
  • Page 123 9.4 — Parts Lists and Drawings Honeywell Control Package Quantity Item Part No. Description 833-1278 Base Controller 833-1335 Control, Keyboard Display Module 833-1276 Controller, Program 832-1067 Amplifier, Infrared, 3 Second, Non Self Check 832-1069 Amplifier, Ultra Violet, 3 Second 832-1070 Timer, 30 Second 832-1065 Timer, 60 Second...

  • Page 124: Damper Assembly D42

    Parts Lists and Drawings 9.4.11 — Damper Assembly D42 - 420 9-24 750-204 Profire D/LND...
  • Page 125 9.4 — Parts Lists and Drawings Damper Assemblies Quantity Item Part No. Description 427-42 Damper Assembly, Air 427-40 Damper Assembly, Air 427-41 Damper Assembly, Air 32-1124 Gasket 32-1125 Gasket 32-1127 Gasket (varies) 8-1272 Bracket, Damper High Fire Switch 836-301 Switch, High Fire Air Interlock 2-141 Arm, Linkage Assembly 2-259...

  • Page 126: Damper Assembly Lnd42

    Parts Lists and Drawings 9.4.12 — Damper Assembly LND42 - 420 9-26 750-204 Profire D/LND...
  • Page 127 9.4 — Parts Lists and Drawings Damper Assemblies Quantity Item Part No. Description 427-117 Damper Assembly, Air 4” FGR Inlet 427-127 Damper Assembly, Air 6” FGR Inlet 427-113 Damper Assembly, Air 6” FGR Inlet 427-129 Damper Assembly, Air 8” FGR Inlet 427-114 Damper Assembly, Air 8”...

  • Page 128: Drawer Assembly D42

    Parts Lists and Drawings 9.4.13 — Drawer Assembly D42 - 63 9-28 750-204 Profire D/LND...
  • Page 129 9.4 — Parts Lists and Drawings Drawer Assemblies Quantity Item Part No. Description 277-139 Nozzle Body Assembly, 22 MM X 1.5 MM Nozzle Thds. All Models Except DE, DEG 277-105 Nozzle Body Assembly, 1-1/8” - 16 Nozzle Thds. Models DE, DEG 82-33 Spring, Nozzle Compression .5”...

  • Page 130: Drawer Assembly D84

    Parts Lists and Drawings 9.4.14 — Drawer Assembly D84 - 145 9-30 750-204 Profire D/LND...
  • Page 131 9.4 — Parts Lists and Drawings Drawer Assemblies Quantity Item Part No. Description 106-101 Block, Oil Air Inlet Manifold 853-613 O-Ring, 5/8” O.D. X 3/32 Thk. 90-241 Tube Assembly, Oil Nozzle Deliver 817- Varies 90-338 Tube, Scanner, Sight 9” 928-44 Clamp, Conduit 1/2”...

  • Page 132: Drawer Assembly D175

    Parts Lists and Drawings 9.4.15 — Drawer Assembly D175 - 336 9-32 750-204 Profire D/LND...
  • Page 133 9.4 — Parts Lists and Drawings Drawer Assemblies Quantity Item Part No. Description 106-101 Block, Oil Air inlet Manifold 853-613 O-Ring, 5/8” O.D. X 3/32 Thk. 90-241 Tube Assembly, Oil Nozzle Deliver 817- Varies 90-339 Tube, Scanner, Sight 9” 928-44 Clamp, Conduit 1/2”...

  • Page 134: Drawer Assembly D378

    Parts Lists and Drawings 9.4.16 — Drawer Assembly D378 - 420 9-34 750-204 Profire D/LND...
  • Page 135 9.4 — Parts Lists and Drawings Drawer Assemblies Quantity Item Part No. Description 817- Varies 106-101 Block, Oil Air Inlet Manifold 928-80 Clamp, Conduit 3/4” 8-1627 Bracket, Scanner Mount 90-338 Tube, Scanner, Sight 9” 853-613 O-Ring, 5/8” O.D. X 7/16” I.D. X 3/32” Thk. 7-196 U-Bolt, 3/4”...

  • Page 136: Firing Head Assembly D42

    Parts Lists and Drawings 9.4.17 — Firing Head Assembly D42 - 420 9-36 750-204 Profire D/LND...
  • Page 137 9.4 — Parts Lists and Drawings Firing Head Assemblies Quantity Item Part No. Description 257-156 Manifold Assembly, Gas Firing Head 257-157 Manifold Assembly, Gas Firing Head 257-147 Manifold Assembly, Gas Firing Head 257-148 Manifold Assembly, Gas Firing Head 257-149 Manifold Assembly, Gas Firing Head 257-153 Manifold Assembly, Gas Firing Head 257-154...

  • Page 138: Oil Air Tank Dl, Dm42

    Parts Lists and Drawings 9.4.18 — Oil Air Tank DL, DM42 - 145 Oil Air Tank Assemblies Quantity Item Part No. Description 941-187 Valve, Needle, Shutoff 850-3 Gauge, Pressure 0 - 60 PSI 195-256 Tank Assembly, Air Oil 350 Cu. In. 940-1200 Valve, Check 1/4”...

  • Page 139: Oil Heater D42 -420

    9.4 — Parts Lists and Drawings 9.4.19 — Oil Heater D42 -420 9-39 750-204 Profire D/LND...
  • Page 140 Parts Lists and Drawings Heater Quantity Item Part No. Description 832-690 Heater, Electric, Oil 3KW 230/3/60 832-689 Heater, Electric, Oil 5KW 230/3/60 832-724 Heater, Electric, Oil 7KW 230/3/60 832-717 Heater, Electric, Oil 10KW 230/3/60 832-718 Heater, Electric, Oil 10KW 440/3/60 77-200 Spacer, Auxiliary Heater Shim 257-70...

  • Page 141: Oil Metering Assembly Dl, Dlg, Dm, Dmg42

    9.4 — Parts Lists and Drawings 9.4.20 — Oil Metering Assembly DL, DLG, DM, DMG42 - 145 9-41 750-204 Profire D/LND...
  • Page 142 Parts Lists and Drawings Oil Metering Assemblies Quantity Item Part No. Description 894-1289 Motor, 1 HP, Models DL, DLG 894-1295 Motor, 2 HP, Models DL, DLG 894-1289 Motor, 1 HP, Models DM, DMG 894-1295 Motor, 2 HP, Models DM, DMG 40-296 Housing, Mounting Oil Pump to Motor 19-342...

  • Page 143: Oil Metering Assembly Dl, Dlg, Dm, Dmg175-420 & De, Deg42

    9.4 — Parts Lists and Drawings 9.4.21 — Oil Metering Assembly DL, DLG, DM, DMG175-420 & DE, DEG42 - 420 9-43 750-204 Profire D/LND...
  • Page 144 Parts Lists and Drawings Oil Metering Assemblies Quantity Item Part No. Description 894-934 Motor, 1/2 HP 894-936 Motor, 3/4 HP 40-296 Housing, Mounting Oil Pump to Motor 19-342 Cover, Drive Coupling Access 819-114 Coupling, Drive 9/16” X 5/8” Bore 819-105 Coupling, Drive 5/8”...
  • Page 145 9.4 — Parts Lists and Drawings Oil Metering Assemblies Quantity Item Part No. Description 894-936 Motor, 3/4 HP 40-296 Housing, Mounting Oil Pump to Motor 19-342 Cover, Drive Coupling Access 819-105 Coupling, Drive 5/8” X 5/8” Bore 695-112 Metering Head Assembly, Oil #300L 282-13 Stop Ass’y, Override, Metering Head 476-53...

  • Page 146: Oil Metering Assembly D378

    Parts Lists and Drawings 9.4.22 — Oil Metering Assembly D378 - 420 9-46 750-204 Profire D/LND...
  • Page 147 9.4 — Parts Lists and Drawings Oil Metering Assembly Quantity Item Part No. Description 894-928 Motor, 1 HP 921-526 Sheave, BC38, 5/8” Bore 8-1633 Bracket, Assembly, Metering Head 29-1149 Flange, Oil Metering Adaptor 695-112 Metering Head Assembly, Oil #300L 282-13 Stop Assembly, Override, ‘E’...

  • Page 148: Modulation, Standard

    Parts Lists and Drawings 9.4.23 — Modulation, Standard Standard Modulation Quantity Item Part No. Description 894-1345 Motor Modulation, 120V, 35 Sec. 894-1346 Motor Modulation, 24V, 30 Sec. 18-149 Collar, Steel 807-335 Bearing, Flanged 2 PT, 3/4” Shaft 807-341 Bearing, Flanged 2 PT, 3/4” Shaft 10-309 Bushing, Mod.

  • Page 149: Modulation, Standard Low Nox Or Left Hand Gas

    9.4 — Parts Lists and Drawings 9.4.24 — Modulation, Standard Low NOx or Left Hand Gas Standard Modulation Quantity Item Part No. Description 894-1345 Motor Modulation, 120V, 35 Sec. 894-1346 Motor Modulation, 24V, 30 Sec. 18-149 Collar, Steel 807-335 Bearing, Flanged 2 PT, 3/4” Shaft 807-341 Bearing, Flanged 2 PT, 3/4”...

  • Page 150: Modulation, Cam Trim

    Parts Lists and Drawings 9.4.25 — Modulation, Cam Trim Standard Modulation Quantity Item Part No. Description 894-1345 Motor Modulation, 120V, 35 Sec. 894-1346 Motor Modulation, 24V, 30 Sec. 18-149 Collar, Steel 807-335 Bearing, Flanged 2 PT, 3/4” Shaft 807-341 Bearing, Flanged 2 PT, 3/4” Shaft 10-322 Bushing, Mod.
  • Page 151 9.4 — Parts Lists and Drawings Standard Modulation Quantity Item Part No. Description 894-1346 Motor, Modutrol, 24V, 30 Sec. 807-341 Bearing, Flanged 2 PT, 3/4” Shaft 10-309 Bushing, Mod. Motor Control Arm, 12” LG 2-259 Arm, Linkage, 3/4” Shaft, 6 Holes 82-153 Spring, Roller Guide, Cam 36-111...

  • Page 152: Modulation, Cam Trim Low Nox Or Left Hand Gas

    Parts Lists and Drawings 9.4.26 — Modulation, Cam Trim Low NOx or Left Hand Gas 9-52 750-204 Profire D/LND...
  • Page 153 9.4 — Parts Lists and Drawings Standard Modulation Quantity Item Part No. Description 894-1345 Motor Modulation, 120V, 35 Sec. 894-1346 Motor Modulation, 24V, 30 Sec. 18-149 Collar, Steel 807-335 Bearing, Flanged 2 PT, 3/4” Shaft 807-341 Bearing, Flanged 2 PT, 3/4” Shaft 10-322 Bushing, Mod.
  • Page 154 Parts Lists and Drawings Modulation Quantity Item Part No. Description 894-1346 Motor, Modutrol, 24V, 30 Sec. 807-341 Bearing, Flanged 2 PT, 3/4” Shaft 10-322 Bushing, Mod. Motor Control Arm, 12” LG 2-259 Arm, Linkage, 3/4” Shaft, 6 Holes 82-153 Spring, Roller Guide, Cam 36-111 Guiide, Cam Spring 71-24...
  • Page 155 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 Cleaver-Brooks in order to validate the warranty of the burner. _______________ _______________ _______________...
  • Page 156 750-204 Profire D/LND...
  • Page 157 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 repre- sented 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 com- petent supervised operators.
  • Page 158 Company's warranty 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.

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