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Manual Part No. 750-437

/2019

ProFire Q

Full Modulation Burner

with UV flame detection

Installation

Operation

Maintenance

Table Of Contents

Содержание ProFire Q Series

Страница 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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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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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