CleaverBrooks ProFire Q Series, Installation Operation & Maintenance

Page 1: ...Manual Part No 750 437 07 2019 ProFire Q Full Modulation Burner with UV flame detection Installation Operation Maintenance Table Of Contents...

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Page 3: ...l 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 sy...

Page 4: ...ng 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 O...

Page 5: ...on 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 CHAPTER 6 Tro...

Page 6: ...able 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 Associati...

Page 7: ...0 Hz 7 See spare parts list for orifice plate part numbers Burner Model Gas Input MBtu hr BHP 80 Eff Blower Motor HP Furnace Pressure w c Air Inlet Orifice Size in 7 Minimum Gas Pressure Required in I...

Page 8: ...r 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 inch...

Page 9: ...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...

Page 10: ...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...

Page 11: ...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 boil...

Page 12: ...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 illumin...

Page 13: ...control fan speed air volume 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 wi...

Page 14: ...System 1 5 Firing Head Access to the firing head is provided by the side access panel Item Component Details 1 Ignition Transformer Step up secondary high voltage ignition transformer 2 Ignition Cabl...

Page 15: ...a UV Scanner FIGURE 1 5 Burner Housing Exploded View ELECTRODE BURNER HOUSING ORIFICE PLATE BAFFLE PLATE GAS MANIFOLD 750 00509 001 UV SCANNER 750 00517 001 ELECTRODE LOCK WASHER NUT UV SCANNER SCREW...

Page 16: ...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 th...

Page 17: ...ating 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 Whe...

Page 18: ...Introduction 1 8 750 437 Q Series Full Modulation...

Page 19: ...g 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 A ga...

Page 20: ...uate 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 2 5 C...

Page 21: ...in Combustion Chamber Min Width in Combustion Chamber Min Length 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 Q...

Page 22: ...l 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...

Page 23: ...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...

Page 24: ...f 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 Associat...

Page 25: ...revent 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...

Page 26: ...ice 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...

Page 27: ...n 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 d...

Page 28: ...Installation 2 10 750 437 Q Series Full Modulation...

Page 29: ...1 2 Burner Settings To ensure reliable and safe burner performance the fan speed and gas settings must be checked and adjusted prior to placing the burner into initial service or after conducting any...

Page 30: ...overview of the control s normal sequence of operation is provided herein Refer to the LMV37 manual for additional sequence of operation detail and the burner wiring diagram to a better understanding...

Page 31: ...djusted for ignition Ph 36 Ignition 38 Ignition transformer energized Ph 38 Main fuel 40 Fuel valve Ph 40 Ignition main flame 42 Ignition Ph 42 Delay before modulating 44 Interval 1 pilot stabilizatio...

Page 32: ...ger to rid it of any possible accrued flammable vapors The control displays Ph30 XX X where XX X is the countdown in seconds Ph36 Traveling to ignition position Airspeed and gas valve opening are posi...

Page 33: ...isplays OFF close the gas train s shutoff and main leak test manual valves Automatic operation can not resume until the operator has determined it is safe to operate the system and returns the gas val...

Page 34: ...ge For example for a setpoint of 5 0 the Plated spring 3 6 range is preferable to the Pink spring 3 8 range 3 4 Gas Train Leak Test Note In this section AZL display text is shown in brackets e g OFF A...

Page 35: ...gas pressure switch 3 to the lowest setting Set the high gas pressure switch 6 to its highest setting and press its reset NOTE gas pressure switches will be tested and set following the LMV37 commiss...

Page 36: ...hutdown should de energize close both safety shutoff valves 4 and 5 If a safety shutoff valve fails to close close the manual shutoff valve 1 Do not proceed further until you correct the problem If 4...

Page 37: ...continued attention to levels is advised Most codes limit permissible CO amounts to below 400 PPM 3 5 2 Efficiency and Stack Temperature A high net stack temperature indicates wasted heat Net stack t...

Page 38: ...hand to keep a written record of the settings Final setting values should be recorded in the startup service report found at the back of this manual The Q burner LMV3 has ignition point P0 and fuel cu...

Page 39: ...set button for 1 to 3 seconds To access LMV3 parameters you ll need to enter the password YYYYY Press and hold VSD F A until the control displays CodE The display then changes and appears with a flash...

Page 40: ...PArA followed by 400 SEt 400 flashing An incorrect entry attempt will display Error then OFF If the attempt fails repeat the steps from the beginning of this section Note The following conditions will...

Page 41: ...ry be certain to check fuel valve actuator coupling for tightness before making any adjustments to fuel or air Be certain the valve is fully closed when the control indicates 0 degrees open The instal...

Page 42: ...e Otherwise continue to c C Failed ignition Reset LMV Following a failed light off attempt the burner locks out and displays alternating error fault messages Loc c X and Loc d Y Turn burner switch OFF...

Page 43: ...y between 2 12 open If the gas valve position needs adjust ment hold down A the display shows 0A GG c with GG c value flashing Increase the gas value by an increment of 2 0 until clean ignition is ach...

Page 44: ...me ignition transformer OFF Ph44 Interval 1 If light off fails return and repeat from step d If light off is successful the controller halts the sequence and displays P0 GG G P0 is blinking P0 may be...

Page 45: ...ws the high fire rate limit parameter 546 XXX where 546 is flashing This value is typically 100 To change it press enter and adjust with or Press enter to save the new value and press ESC to return to...

Page 46: ...g Press ESC 000 Int 000 flashing Press until control displays 400 Set 400 flashing Commissioning and backup are complete J Logout exit Parameter Settings With the display showing 400 Set 400 flashing...

Page 47: ...er switch to OFF reopen the main shutoff cock 1 reset the low gas pressure switch 3 and reset the LMV via the AZL reset button in preparation for the next step 3 7 2 Test the high gas pressure switch...

Page 48: ...m Decrease S Sy t stem D Decrease SYSTEM 147 o F TARGET 150o F DECREASE SYSTEM INCREASE T1 COM T2 COM T3 T3 EXT EXT P P COM 24VAC POWER BLACK BOILER ACTIVATION YELLOW 120 VAC OPERATING CONTROL COMMON...

Page 49: ...68 F TARGET 150 F SET SET CONTROL MODE Outdoor Reset Set Point SENSOR TYPE Temp 230F Pres 30psi Pres 100psi Pres 200psi Pres 300psi 100psiVacuum 30in Humidity RH Temp 110C Pres 0 250MPa Pres 0 600MPa...

Page 50: ...Operation 3 22 750 437 Q Series Full Modulation...

Page 51: ...djustments are required in a particular installation 4 2 Gas System 4 2 1 Honeywell V48A Gas Valve Adjustment 1 The bleed valve screw should be open one 1 turn counterclockwise from the fully closed p...

Page 52: ...tility can provide this information as well as pressure correction factors To determine the required number of cubic feet per hour of gas divide burner input Btu hr by the heating value Btu cu ft Exam...

Page 53: ...ly anchored before testing adjusting or running the burner or burner related equipment It is important to provide support for the panel cover when in the open position to prevent damage to the hinges...

Page 54: ...harmed by discoloration Never use files or abrasive materials such as sandpaper on contact points 5 2 1 LMV3 Control This control requires no adjustment nor should any attempt be made to alter contac...

Page 55: ...trode clean and properly set can cause faulty operation The electrode assembly is supported by a socket in the diffuser and gas inlet tube No adjustment is required except proper positioning of the el...

Page 56: ...ized valve if it fails to operate After replacement and with the fuel supply off cycle the motorized valve and confirm that it opens and closes If the valve has a visual indicator observe its position...

Page 57: ...rly to assure adequate cooling 5 10 2 Fuse Replacement 5 11 Extended Shutdown When shutting down the burner for an extended period of time the operator should use the following general guidelines to p...

Page 58: ...e audible and visual check Check valve position indicators and check fuel meters Flame Failure Controls Operator Close manual fuel supply valve s Check safety shutdown timing Record in log Flame Signa...

Page 59: ...splay a code indicating the failure condition Refer to the LMV3 troubleshooting section included here for details A thorough knowledge of the system and its controls will facilitate the troubleshootin...

Page 60: ...f valves 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 startin...

Page 61: ...ircuit not completed a Fuel valve auxiliary switch not closed 5 Blower motor not operating a Blower motor fuse is blown No Ignition 1 Lack of spark a Electrode grounded or porcelain cracked b Improper...

Page 62: ...he most recent fault Parameter 703 displays information about the second most recent fault Parameter 725 displays information about the 24th most recent fault Burner Stays in Low Fire 1 Pressure or te...

Page 63: ...ex 04 Phase Index 05 Start number Index 06 Load Index 07 Fuel LMV36 only Often index 05 and index 06 will display a value of _ _ This means that the AZL display ran out of room to display the start nu...

Page 64: ...only be set to 2 on pneumatic fuel train options 4 Air pressure on prevention of startup The air pressure switch input is energized preventing the LMV3 from starting up If other inputs besides the ai...

Page 65: ...o 50 of the inlet pressure to the upstream valve 83 Fuel valve 2 V2 leaking The downstream gas valve failed valve proving 1 Bubble test the gas valve to ensure the valve is not leaking If the valve is...

Page 66: ...Gas shortage prevention of startup The low gas pressure switch was not made by the end of phase 22 preventing the startup of the LMV3 See diagnostic code 0 for more corrective actions 21 Any Pressure...

Page 67: ...pressure start prevention 65 Safety loop burner flange open POC start prevention 67 Safety loop burner flange open extraneous light POC start prevention 69 Safety loop burner flange open air pressure...

Page 68: ...fault The LMV36 is currently in the process of changing from fuel 1 to fuel 0 1 Fuel 1 No fault The LMV36 is currently in the process of changing from fuel 0 to fuel 1 62 Fuel Err Any Invalid fuel si...

Page 69: ...set the fault 2 If the fault persists and a VSD is present restandardize the VSD and reset the fault 3 If the fault occurs continuously replace the LMV3 1 Current output different 2 Target output diff...

Page 70: ...sor The gap should be about 1 16 2mm or about two turns away from the speed wheel 3 Check the wiring of the speed sensor Ensure the reference ground is properly connected 4 Ensure that other metal par...

Page 71: ...a higher value than parameter 662 neutral zone 3 Check the absolute speed parameter 935 to ensure the correct speed is being detected by the LMV3 128 VSD speed exceeds maximum speed phase dependent 1...

Page 72: ...613 00 fuel 0 and 614 fuel 1 to ensure the actuator type is set correctly 2 Check to see if the actuator gets bound somewhere along its working range This can be done changing the home position of the...

Page 73: ...alve 1 5 Relay contacts have welded fuel valve 2 6 Relay contacts have welded pilot valve 97 Any Error relay supervision 0 Safety relay contacts have welded or external power supply fed to safety rela...

Page 74: ...04 1 106 Any Internal error contact request If the fault occurs continuously replace the LMV3 107 Any Internal error contact request 108 Any Internal error contact request 110 Any Internal error volta...

Page 75: ...ously replace the LMV3 129 Any Internal error EEPROM access command synchronization Reset the fault and check to make sure the last parameter that was viewed changed is set properly If the fault occur...

Page 76: ...valid so the restore could not be completed Reset the fault 248 8 Restore cannot at present be made Reset the fault and repeat the restore 249 7 Restore abortion due to unsuitable burner identificatio...

Page 77: ...number example 21 point P1 41 49 Fuel 1 Minimum value VSD curve invalid Fuel 1 A VSD curve point is below the permissible minimum value diagnostic code point number example 41 point P1 61 69 Fuel 1 M...

Page 78: ...nagement 171 Any Internal error management If the fault occurs continuously replace the LMV3 200 OFF Any System error free The LMV3 displays this code when there are no current faults 201 OFF UPr0 OFF...

Page 79: ...n the diagnostic code Be sure that the new unit has up to date software 0 LMV3 version is too old 1 AZL23 version is too old 208 Any Internal error If the fault occurs continuously replace the LMV3 20...

Page 80: ...res the burner identification parameter 113 and LMV product no with the burner identification and product no of the backup data set If the data is consistent with the equipment they are restored If no...

Page 81: ...2 time main valve and pilot valve on before pilot off 5 232 Gas Interval 2 main flame establishment 5 233 Time allow see flame after turned off 3 234 Postpurge Time 3 236 Gas Pressure switch min input...

Page 82: ...Troubleshooting 6 24 750 437 Q Series Full Modulation...

Page 83: ...ail yes passed Test readings enter values Test Conducted at Gas Firing Rate Low 50 High Firing Rate MMBH Flame Signal Reading Steam Pressure PSIG Water Temperature F Room Temp F Stack Temp gross F O2...

Page 84: ...750 437 Q Series Full Modulation Contacts Cleaver Brooks Technical Support Phone 800 250 5883 Email cleaverbrooks com...

Page 85: ...ment 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 i...

Page 86: ...pany s liability for breach of implied if any and express warranties representations instructions or defects from any cause in connection with the sale or use of the equipment THE COMPANY SHALL NOT BE...

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