Cleaver-Brooks Profire E Series, Installation Operation & Maintenance

Page 1: ...Manual Part No 750 297 07 2019 Profire E LNE Burner Light Oil Gas or Combination Installation Operation Maintenance Table Of Contents...

Page 2: ...E LNE SERIES Installation Operation and Service Manual Manual Number 750 297 Release Date July 2019...

Page 3: ...d 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...

Page 4: ...as Association CGA B149 and Canadian Standard Association CSA B140 and B139 for oil burners codes shall prevail OIl and gas burning equipment shall be connected to flues having sufficient draft at all...

Page 5: ...000 4 30 15 1 460 3 Standard Specifications for EG EL ELG Series Gas 2 Oil Gas Oil Configuration Burner Model Standard Gas Train Pipe Size in Gas Pressure Required PSI E 84 1 2 1 2 2 1 E 105 1 3 2 2...

Page 6: ...Low NOx Standard Specifications for LNEG LNELG Series Gas Gas Oil Configuration Burner Model Frame Size Standard Gas Train Pipe Size Gas Pressure Required PSI FGR Line Piping Size LNE 84 1 2 1 2 2 1...

Page 7: ...SUPPORT 23 1 4 31 1 2 33 5 8 E MOUNTING FLANGE TO GAS INLET 3 3 4 5 6 5 8 F CENTER LINE TO HINGE 8 7 8 10 3 16 11 11 16 G OUTER DIAMETER 21 26 30 H INNER DIAMETER 13 3 8 16 19 I DIAMETER OF BOLT CIRCL...

Page 8: ...8 10 3 16 11 11 16 G OUTER DIAMETER 21 26 30 H INNER DIAMETER 13 3 8 16 19 I DIAMETER OF BOLT CIRCLE 19 1 4 24 28 1 4 J NUMBER OF MOUNTING HOLE 8 12 8 K DIAMTER OF BOLT HOLE 3 4 15 16 3 4 L OFFSET OF...

Page 9: ...3 1 4 Combustion Air Handling System 1 3 1 5 Firing Head 1 3 1 6 Oil System Air Atomizing 1 4 1 6 1 3 Way Solenoid Valve 1 4 1 6 2 Nozzle Assembly 1 4 1 6 3 Oil Strainer 1 4 1 6 4 Atomizing Air Provin...

Page 10: ...op 2 7 2 7 Oil Circulating Loop Operation 2 8 2 8 Circulating Oil Pump 2 11 2 9 Back Pressure Valve 2 11 2 10 Gas Piping 2 11 2 11 Installation Checklist 2 12 CHAPTER 3 Operation 3 1 3 1 Preparations...

Page 11: ...Adjustments 4 2 4 2 4 Fuel Oil Adjustments 4 2 4 3 Electrical Interference Test 4 2 4 3 1 Gas Fired 4 2 4 3 2 Oil Fired 4 2 4 4 Gas System 4 3 4 4 1 Gas Pressure 4 3 4 4 2 Gas Flow 4 3 4 4 3 Gas Pilo...

Page 12: ...aintenance 5 1 5 1 Overview 5 1 5 2 Control System 5 1 5 2 1 Programming Control 5 2 5 3 Impeller and Inlet Cone 5 2 5 4 Firing Head Inspection 5 2 5 5 Pilot and Ignition Electrode 5 3 5 6 Flame Scann...

Page 13: ...13 4 Gas Pressure Switches 5 9 5 14 Electrical System 5 8 5 14 1 Electric Motors 5 8 5 15 Checking Flame Failure 5 8 5 15 1 Pilot Flame Failure 5 8 5 15 2 Failure to Light Main Flame 5 8 5 15 3 Loss...

Page 14: ...ries Manual CHAPTER 8 LNE Series FGR System 8 1 8 1 Description 8 1 8 2 FGR Shutoff Valve 8 2 8 3 FGR Control Valve 8 2 8 4 Air FGR Damper Assembly 8 4 8 5 Stack Temperature Interlock 8 4 STARTUP SERV...

Page 15: ...light oil The E series oil burners are of the low pressure air atomizing nozzle type while the gas burners are of the peripheral mix type The E series burner operates with full modulation on gas light...

Page 16: ...om oil to gas fuel allow the programmer to complete post purge and shutdown before moving the selector switch to the gas position This will allow the interlock circuit to de energize at either the oil...

Page 17: ...to the open position An internal gas pilot is standard on all burners Pilot gas pressure is adjusted at the pilot pressure regulator FIGURE 1 1 Burner Housing Component Details Damper Assembly A rota...

Page 18: ...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 the atomizing air Ato...

Page 19: ...r enters the compressor through the filter The air flows from the compressor into the air oil separating and reservoir tank Filtering material and baffles separate the lube oil from the compressed air...

Page 20: ...g valve at the manifold inlet The valve is actuated by an adjustable linkage from the modulating motor Depending upon specific requirements one or two safety shutoff motorized main gas valves are prov...

Page 21: ...put 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...

Page 22: ...nce only and are subject to change without notice Optional equipment may change a layout Component Description Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to t...

Page 23: ...ge by the modulating motor The air control damper is positioned simultaneously by the modulating motor The automatic gas valve s cannot be energized unless the combustion air proving switch is closed...

Page 24: ...Introduction 1 10 750 297 Profire E LNE Series Manual...

Page 25: ...panel Wiring from the panel to burner mounted components is installed at the factory Wiring from the burner panel to boiler controls low water controls remote compressor motor and remotely located fue...

Page 26: ...hamber Min Width Combustion ChamberMin Length 84 10 19 19 31 5 64 3 5 23 38 74 105 10 19 23 31 5 64 3 5 23 46 84 126 10 19 24 31 5 64 3 5 23 50 90 147 12 22 25 31 5 64 3 5 23 55 100 168 12 27 5 27 37...

Page 27: ...Boiler Dimensions Burner Model Boiler HP A B 84 200 34 115 105 250 34 144 126 300 38 158 147 350 38 185 168 400 42 155 210 500 42 195 252 600 46 194 294 700 48 204 336 800 50 230 378 900 60 230 420 1...

Page 28: ...9 SIZE 1 A A Q16 00 15 30 12X 30 12X Q29 75 Q31 50 Q 69 12X Q24 00 A A 22 5 16X 45 8X Q 81 16X Q33 25 Q28 25 Q19 00 SIZE 2 SIZE 3 A 45 90 SECTION A A B C D E F G H I J K SIZE 1 SIZE 2 SIZE 3 A 25 39 2...

Page 29: ...ory dry oven sized for a specific heat exchanger or a standard refractory dry oven sized per Figure 2 3 If a refractory dry oven was not purchased with the burner the installer must provide one The dr...

Page 30: ...of the dry oven with ceramic fiber blanket while leaving a 1 space from the dry oven s front edge to the blanket wrap The wrap must fill the gap between the refractory outside diameter and the firetub...

Page 31: ...enough to prevent restriction of flow through any cold spots in the system Note that the supply line is approximately 20 inches or higher above the burner metering pump inlet to help eliminate air pr...

Page 32: ...flows through a bypass section of the oil metering pump Metered oil passes through the metering section to a de energized 3 way oil valve common port Both unmetered and metered oil must pass through...

Page 33: ...SIZE LOW OIL PRESSURE SWITCH NO 2 OIL RETURN SUCTION GATE VALVE OIL METERING PUMP SUPPLIED WITH BURNER PRESSURE GAUGE NEEDLE VALVE STRAINER CHECK VALVE VACUUM GAUGE STRAINER GATE VALVE GATE VALVE GAT...

Page 34: ...METERING PUMP SUPPLIED WITH BURNER PRESSURE GAUGE NEEDLE VALVE STRAINER CHECK VALVE VACUUM GAUGE STRAINER GATE VALVE GATE VALVE GATE VALVE PIPING BY OTHERS PIPING BY I C 2 WAY VALVE ON BURNER BACK PR...

Page 35: ...e spring screwing down the screw you increase the set pressure within the limits of the spring range Reversing the setscrew lowers the set pressure Adjust to 10 15 PSI for No 2 oil systems When the de...

Page 36: ...y component be sure the supply voltage is the same as that specified on component nameplates Before burner operation be sure all motors are rotating in the correct direction Before firing make sure th...

Page 37: ...te voltage on all motors and the control circuit Check the direction or rotation of the motors Open the housing to check the electrode setting Check the gas pilot pressure at the pilot gas regulator T...

Page 38: ...w diagrams in Chapter 1 indicate the flow of fuel and atomizing air If the burner is a dual fuel model make certain that the main gas shutoff cock is closed and the fuel selector switch is set to OIL...

Page 39: ...to 6 W C when the pilot is burning 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 pilot flame obtai...

Page 40: ...ner motor stops close all manual valves 3 7 Safety Shutdown 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 pu...

Page 41: ...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 10 T...

Page 42: ...re 10 Turn the manual potentiometer switch to the HIGH FIRE position Check the high fire combustion at this point Do not disturb previously established low fire adjustment 11 Allow the burner to retur...

Page 43: ...own 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 indicato...

Page 44: ...Operation 3 8 750 297 Profire E LNE Series Manual...

Page 45: ...ustment on Gas and Oil 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...

Page 46: ...al Interference Test Prior to putting the burner into service conduct the following test to ascertain that ignition spark will not cause the flame relay to pull in 4 3 1 Gas Fired 1 Close the pilot an...

Page 47: ...f the pilot 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...

Page 48: ...g manufacturer s directions for regulator adjustment When proper gas flow is obtained take a flue gas analysis reading With the high fire air fuel ratio established the gas pressure regulator needs no...

Page 49: ...ise pressure setting The minimum amount of atomizing air is during pre and post purge During pre purge adjust switch until it breaks the circuit Readjust the switch above this circuit breakpoint to ac...

Page 50: ...ex socket end to decrease it A 3 32 hex key is required It will be necessary to cut off the short end of a hex key to approximately 3 8 to adjust the first two socket head setscrews at the low fire po...

Page 51: ...ut 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 slowe...

Page 52: ...nual HIGH FIRE POSITION COMBUSTION AIR DAMPER FUEL OIL METERING PUMP MODULATING MOTOR GAS BUTTERFLY VALVE LOW FIRE POSITION COMBUSTION AIR DAMPER FUEL OIL METERING PUMP GAS BUTTERFLY VALVE MODULATING...

Page 53: ...lds as shown in Figure 4 3 The Secondary valve controls the low to mid fire gas and the Primary valve controls the mid to high fire gas 4 10 1 Gas Metering Valve Theory of Operation Figure 4 4 provide...

Page 54: ...ovements of the primary valve through the low to mid fire range and nominal movements of the secondary valve through the mid to high fire range satisfy these controller requirements only the position...

Page 55: ...e 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 cabi...

Page 56: ...are contained in the manufacturer s bulletin 5 3 Impeller and Inlet Cone Proper clearance between the impeller and the inlet housing set at 3 8 nominal Adjust the inlet cone so it is centered in the i...

Page 57: ...tip and keeping the orifice clean Standard nozzle tips furnished on the burners are of a special emulsifying type which delivers a spray of extreme fineness and at an angle which insures proper mixing...

Page 58: ...th a scribed or pencil line where the three mounting screws are located to insure that the diffuser is placed back in the same position 3 Remove the three screws holding the diffuser to the blast tube...

Page 59: ...Suction line piping too small see Chapter 2 Pump rotating in wrong direction Three phase pump motor operating on single phase because of fuse failure Low voltage applied to pump motor 5 11 2 Fuel Oil...

Page 60: ...his purpose Move the top bolt to the next hole and adjust Tighten bolts and setscrews Replace belt guards Replace the belt if it becomes frayed or cracked 5 12 2 Air Cleaner Never operate the compress...

Page 61: ...rough the conical strainer in the pipe with the unit running The oil and its container should be clean Although there is a strainer in the lube oil line its purpose is to remove any unwanted materials...

Page 62: ...late 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 serv...

Page 63: ...our seconds The control will then lock out on a safety shutdown 3 The flame failure light and optional alarm ill be activated The blower motor will run through the post purge period and stop 4 Turn th...

Page 64: ...ame Signal Strength Controls Operator Read and log the flame signal for both pilot and main flame Notify Service if readings are very high very low or fluctuating Linkages Operator Check all burner li...

Page 65: ...e 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...

Page 66: ...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 The ca...

Page 67: ...t 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...

Page 68: ...Binding or loose linkages cams setscrews etc 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 Sca...

Page 69: ...o open or close during pre purge or close on burner shutdown a Motor defective b Loose electrical connection c Damper motor transformer defective 4 Motor does not operate on demand a Manual automatic...

Page 70: ...Troubleshooting 6 6 750 297 Profire E LNE Series Manual...

Page 71: ...7 1 CHAPTER 7 Accessories 7 1 Overview The E Series burners are available with a wide selection of accessories This section will cover some of the most popu lar accessories 7 2 Steam Atomizing System...

Page 72: ...urging screw in and adjust the needle valve to have 10 15 PSI in low fire Install a pressure gauge to monitor the pressure One or two regulator is supplied depending on the boiler operating steam pres...

Page 73: ...750 297 Profire E LNE Series Manual 7 3 Accessories FIGURE 7 3 Plant Air System Top Loaded with Air FROM AIR SUPPLY AIR FLOW WIRE TO FLAME SAFEGUARD BLOWER MOTOR TERMINAL...

Page 74: ...em Top Loaded with Oil WIRE TO FLAME SAFEGUARD BLOWER MOTOR TERMINAL FROM AIR SUPPLY AIR FLOW OIL PRESSURE DOWN STREAM OF OIL METERING VALVE NOZZLE PRESSURE TO TOP LOAD AIR PRESSURE REGULATING VALVE N...

Page 75: ...t it into the combustion zone Typical sizing for the FGR ducts are shown in Figure 8 4 All FGR duct piping should be covered with a minimum of 2 of insulation and supported as required The following c...

Page 76: ...urner mounted modutrol motor with link age connections coordinates the air fuel and NOx control devices to provide proper fuel air NOx ratios through the firing range The modutrol motor must be able t...

Page 77: ...97 Profire E LNE Series Manual 8 3 LNE Series FGR System FIGURE 8 3 FGR Control Valve and Control Positions FGR HIGH FIRE MODULATING MOTOR FGR CONTROL VALVE FGR LOW FIRE MODULATING MOTOR FGR CONTROL V...

Page 78: ...ue gas is pulled into the regulated combustion air flow above the damper blade as controlled by the FGR control valve Combustion air mixed with flue gas is passed on through the blast tube to the comb...

Page 79: ...750 297 Profire E LNE Series Manual 8 5 LNE Series FGR System FIGURE 8 4 Temperature Interlocks...

Page 80: ...8 8 10 10 10 12 LNE 147 8 8 8 8 10 10 10 12 LNE 168 10 10 10 10 12 12 14 14 LNE 210 10 10 10 10 12 12 14 14 LNE 252 10 10 10 10 12 12 14 14 LNE 294 12 12 12 12 14 14 16 16 LNE 336 12 12 12 12 14 14 1...

Page 81: ...Temp F Operating Limit O2 High Limit CO Operating Control CO PPM Stack Temp Interlock NOx PPM Flame Failure Smoke Bacharach Combustion Air Switch Combustion Eff High Purge Switch Stack Draft W C Low...

Page 82: ...750 297 Profire E LNE Series Manual...

Page 83: ...pment 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...

Page 84: ...mpany 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 B...