CleaverBrooks Profile LNS1 Series Guide

Manual Part No. 750-208 07/2019
Profire S1/LNS1
Burner
Light Oil, Gas, or Combination
Installation
Operation
Service
Parts
Table Of Contents

Monroe, Wisconsin
www.cleaverbrooks.com

S1/SERIES TABLE OF CONTENTS
SECTION 1:0
OPERATING PRECAUTIONS ................................................1
MODEL DESIGNATIONS, SIZES & INPUTS .........................2
CHAPTER 1. INTRODUCTION
A. GENERAL INFORMATION ................................................3
B. DESCRIPTION ...................................................................3
C. OPERATING CONTROLS .................................................3
D. FLAME SAFEGUARD CONTROLS ...................................4
E. COMBUSTION AIR HANDLING SYSTEM ........................4
F. FIRING RATE CONTROLS................................................4
G. FIRING HEAD ....................................................................4
H. OIL SYSTEM AIR ATOMIZING ...................................... 4-5
I. GAS SYSTEM ................................................................ 6-7
CHAPTER 2. INSTALLATION
A. APPLICATION....................................................................8
B. INSTALLATION ..................................................................8
C. PACKING PLASTIC REFRACTORY AROUND OVEN .....8
D. SEPARATE COMPRESSOR MODULE .............................8
E. TYPICAL OIL SUPPLY LOOP ............................................8
F. CIRCULATING OIL PUMP .................................................8
G. OIL PRESSURE REGULATOR..........................................8
H. GAS PIPING ......................................................................8
MOUNTING SKETCHES. ................................................. 9-10
I. INSTALLATION CHECK LIST ..........................................10
OIL PIPING SCHEMATICS. .................................................11
GAS PIPING SCHEMATICS. ...............................................12
GENERAL ARRANGEMENT ................................................13
MOTOR ROTATION .............................................................14
CAUTION .............................................................................15
CHAPTER 3. OPERATION
A. PREPARATION FOR STARTING ....................................16
B. ELECTRICAL INTERFERENCE TEST ...................... 16-17
C. GAS PILOT FLAME ADJUSTMENT ................................17
D. START-UP SEQUENCE ..................................................17
E. AUTOMATIC SHUTDOWN ..............................................17
F. MANUAL SHUTDOWN ....................................................17
G. SAFETY SHUTDOWN .....................................................17
H. START-UP AND OPERATING. ........................................18
I. NORMAL OPERATION. ....................................................18
J. SHUTDOWN. ....................................................................19
CHAPTER 4. ADJUSTMENTS
A. GENERAL ....................................................................... 20
B. COMBUSTION ADJUSTMENT ON GAS AND OIL...... ...20
C. ELECTRICAL INTERFERENCE TEST.............................20
D. GAS SYSTEM.............................................................20-22
E. OIL SYSTEM...............................................................22-23
F. LINKAGE - MODULATING MOTOR............ .... ................23
G. FIRING RATE CONTROLS.............................. ................23
AIR DAMPER BOX ARRANGEMENT................................. . 24
GAS LINKAGE ADJUSTMENTS................................. ......... 25
OIL LINKAGE ADJUSTMENTS................................. ........... 26
F.G.R. BLADE LINKAGE ADJUSTMENTS........................... 27
AIR DAMPER BLADE LINKAGE ADJUSTMENTS............... 28
CHAPTER 5. MAINTENANCE
A. GENERAL. ....................................................................... 29
B. CONTROL SYSTEM. ....................................................... 29
C. PROGRAMMING CONTROL .......................................... 29
D. FIRING HEAD INSPECTION ........................................... 29
E. PILOT AND IGNITION ELECTRODE .............................. 29
F. FLAME SCANNER. .......................................................... 29
G. OIL NOZZLE .................................................................... 31
H. DIFFUSER ....................................................................... 31
I. FIRING RATE CONTROLS ............................................... 32
J. BURNER MOUNTING INSPECTION. .............................. 32
K. FUEL OIL SYSTEM ......................................................... 32
L. GAS SYSTEM. ................................................................. 32
M. ELECTRICAL SYSTEM ................................................... 33
N. EXTENDED SHUTDOWN. .............................................. 33
O. COMMON VENT LINE .................................................... 33
P. MAINTENANCE FLOW CHART ....................................... 34
CHAPTER 6. TROUBLE SHOOTING
A. AWARENESS. .................................................................. 35
B. EMERGENCY SHUTDOWN. ........................................... 35
TROUBLE SHOOTING GUIDE. ......................................36-38
SECTION 2:0
CHAPTER 7. LOW NOx SYSTEM
A. F.G.R. SHUT-OFF VALVE .................................................. 1
B. F.G.R. DAMPER ASSEMBLY ..........................................2-3
WARRANTY POLICY. .........................................................4-5
START-UP / SERVICE REPORT. ........................................... 6
PRODUCT SATISFACTION SURVEY ................................... 7
SECTION 3:0
PARTS SECTION
FIRING HEAD ASSEMBLY .................................................... 5
HOUSING COMPONENTS .................................................6-7
AIR DAMPER BOX................................................................. 8
AIR DAMPER BOX COMPONENTS .................................9-10
MOD MOTOR ....................................................................... 11
MAXON VALVE .................................................................... 12
GAS BUTTERFLY & LINKAGES .....................................13-14
OIL NOZZLE COMPONENTS .............................................. 15
OIL TRAIN ............................................................................ 16
AIR COMPRESSOR ............................................................. 17

Monroe, Wisconsin
www.cleaverbrooks.com

Sec1:1
This operating manual presents information that will help to properly operate and care
for the equipment. Study its contents carefully. The unit will provide good service and
continued operation if proper operating and maintenance instructions are followed. No
attempt should be made to operate the unit until the principles of operation and all of
the components are thoroughly understood. Only trained and authorized personnel
should be allowed to operate, adjust or repair this equipment.
If you are operating a burner(s), it is your responsibility to ensure that such operation
is in full accordance with all applicable safety requirements and codes.
Placed on all CB Prore burners are warning or caution labels designed to inform the
operator of potential hazards and stress important information.
These symbols and their meanings are as follows:
OPERATING PRECAUTIONS
WARNING
FAILURE TO INSTALL AND OPERATE THIS EQUIPMENT IN ACCORDANCE WITH THE
MANUFACTURERS RECOMMENDED INSTRUCTIONS AND INDUSTRY STANDARDS AND
PRACTICES CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE AND/OR PER-
SONAL INJURY !! READ THIS MANUAL IN IT’S ENTIRIETY PRIOR TO ANY ATTEMPT TO
COMMISSION THIS EQUIPMENT. INSTALLATION, STARTUP, OPERATION AND MAINTE-
NANCE OF THIS EQUIPMENT MUST BE PERFORMED ONLY BY FACTORY AUTHORIZED,
EXPERIENCED AND QUALIFIED PERSONEL.
READ PRODUCT MANUAL AND FULLY
UNDERSTAND ITS CONTENTS
BEFOREATTEMPTING TO OPERATE
THIS EQUIPMENT. SERIOUS PERSONAL
INJURY OR DEATH MAY RESULT.
PROVIDE SUPPORT FOR THIS PANEL
TO PREVENT DAMAGE TO THE
ELECTRICAL COMPONENTS.
CAUTION
ONLY FACTORY AUTHORIZED BURNER
SERVICE PERSONNEL SHOULD
START UP, ADJUST, OR SERVICE THIS
EQUIPMENT.
CAUTION
WARNING
HAZARD OF ELECTRIC SHOCK!!!
MORE THAN ONE DISCONNECT MAY BE
REQUIRED TO DISCONNECT ALL POWER
TO THIS PANEL. SERIOUS PERSONAL
INJURY OR DEATH MAY RESULT.
WARNING
TO AVOID PERSONAL INJURY
FROM MOVING PARTS, SHUT OFF
ALL ELECTRICAL POWER BEFORE
SERVICING THIS EQUIPMENT.
WARNING
AFTER FINAL FUEL INPUT ADJUSTMENTS
ARE MADE, VERIFY FUEL INPUT BY
METER IF POSSIBLE
CAUTION

Sec1:2
Gas input based on natural gas at 1,000
Btu/cu.ft and 0.60 specic gravity
Oil input based on No.2 oil at 140,000Btu/gal
THE INSTALLATION OF A BURNER SHALL BE
IN ACCORDANCE WITH THE REGULATIONS
OF AUTHORITIES HAVING JURISDICTION. THE
EQUIPMENT MUST BE INSTALLED IN ACCORDANCE
WITH APPLICABLE LOCAL, STATE OR PROVINCIAL
INSTALLATION REQUIREMENTS INCLUDING
THE NATIONAL ELECTRICAL CODE (NEC) AND
ASSOCIATED INSURANCE UNDERWRITERS.
WHERE APPLICABLE, THE CANADIAN GAS
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 TIMES, TO ASSURE SAFE AND
PROPER OPERATION OF THE BURNER.
THE S1/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.
DO NOT USE GASOLINE, CRANKASE OIL, OR ANY
OIL CONTAINING GASOLINE.
Model designations are based on the type of fuel(s) to
be red and the amount of furnace pressure to be over-
come. Burner size is based on ring rate (rated input in
BTU/HR).
Further warning and caution references have been
made in this manual and should be adhered to for
smooth operation of the burner.
WARNING
CAUTION
NOTE
This symbol precedes information
which, if disregarded, may result
in injury to the user of the burner
or to others.
This symbol precedes information
which, if disregarded, may result
in damage to the burner.
This symbol precedes information
which is vital to the operation or
maintenance of the burner.
MODELS
STANDARD FUEL - AIR ATOMIZATION
S1G GAS
S1L #2 OIL
S1LG #2 OIL and GAS
LNS1G LOW Nox < 30 ppm GAS
LNS1LG LOW NOx #2 OIL and GAS
BURNER MAX.BURNER GAS INPUT
SIZE MBTU/HR.
462 46,200,000
504 50,400,000
546 54,600,000
588 58,800,000
630 63,000,000
BURNER MAX.BURNER OIL INPUT
SIZE US G.P.H.
462 330
504 360
546 390
588 420
630 450

Sec1:3
CHAPTER 1
INTRODUCTION
Off position: Burner off.
Oil position: Selects oil as the ring fuel.
3. CONTROL CIRCUIT BREAKER - supplementary
low overcurrent protection only. No larger than 15
amps.
4. AUTO-MANUAL
MODULATION SELECTOR SWITCH.
Auto Position: Selects boiler modulation control.
Manual Position: Selects 135 ohm potentiometer
for manual modulating control.
5. MANUAL MODULATING CONTROL 135 ohm
Increases or decreases the burner ring rate
manually.
6. SIGNAL LAMPS.
a. POWER ON (white) illuminates when the control
circuit is energized (powered).
b. IGNITION (amber) illuminates when the ignition
transformer is powered, and gas pilot valve is
energized (opened).
c. MAIN FUEL (green) illuminates when the main
fuel valve or valves (gas or oil) are energized
(open).
d. FLAME FAILURE (red) illuminates when the
ame safeguard system fails to detect pilot or
main ame.
A. GENERAL INFORMATION
CB Prore S1/Series burners are assembled, wired and
tested at the factory. They are listed by the Underwriters
Laboratory, CSD-1, NFPA-85, I.R.I., F.M., including the
National Electrical Code (NEC) and associated insurance
underwriters. Where applicable, the Canadian Gas As-
sociation (CGA) B149 and Canadian Standards Association
(CSA) B140 codes shall prevail. Other regulatory agency
control options are available.
CAUTION
The operator must be familiar with the individual functioning
of all controls to understand the operations and procedures
described in the manual. Identify and locate each item
in the illustrations as they are described in the following
sections.
B. DESCRIPTION
The CB Prore S1/Series oil burners are of the low
pressure, air atomizing (nozzle) type. Gas burners are
of the peripheral mix type. All burners feature ignition by
spark-ignited gas pilot ame. With either fuel, the burner
operates with full modulation. A switch permits changeover
from automatic fully modulated ring to manually set ring
at any desired rate between minimum and maximum. Ad-
ditional safeguards assure that the burner always returns
to minimum ring position for ignition.
S1/Series burners are designed for automatic, unattended
operation except for periodic inspection and maintenance.
After selecting the proper overload settings for the starter,
the rest of the control panel components require little at-
tention except for occasional cleaning.
C. OPERATING CONTROLS
The burner is supplied with a remote control panel and
with a burner mounted junction box.
CONTROL PANEL
The control panel contains a ame safeguard program-
ming control, motor starters, relays, time delays and termi-
nal strips mounted internally on a panel sub-base. Lights,
switches, potentiometers, a control circuit breaker and ame
safeguard displays are mounted externally on the panel as
indicated below.
1. ON-OFF BURNER SWITCH - (for gas or oil only)
2. FUEL SELECTOR SWITCH - Gas-Off-Oil
(for combination gas-oil burners only)
Gas position: Selects gas as the ring fuel .
ONLY FACTORY AUTHORIZED BURNER
SERVICE PERSONNEL SHOULD START-UP,
ADJUST, OR SERVICE THIS EQUIPMENT
WHEN CHANGING FROM OIL TO GAS FUEL,
ALLOW PROGRAMMER TO COMPLETE
POST PURGE AND SHUTDOWN BEFORE
MOVING SELECTOR SWITCH TO GAS PO-
SITION. THIS WILL ALLOW THE INTERLOCK
CIRCUIT TO OIL-AIR PUMP OR COMPRES-
SOR TO DE-ENERGIZE
NOTE
READ THE FLAME SAFEGUARD MANUAL
AND FULLY UNDERSTAND ITS CONTENTS
BEFORE ATTEMPTING TO OPERATE THIS
EQUIPMENT. SERIOUS PERSONAL INJURY
OR DEATH MAY RESULT.
WARNING

Sec1:4
release the housing latch and swing the housing to open
position. An internal gas pilot is standard on all burners.
Pilot gas pressure is adjusted at the pilot pressure regula-
tor.
H. OIL SYSTEM AIR ATOMIZING
S1 Model burners use compressed air for atomization.
Atomizing air is independent of combustion air. The system
is supplied with a separate compressor module for mount-
ing near the burner.
3-WAY SOLENOID VALVE.
Metered oil enters the common port of the 3-way solenoid
valve. During shutdown, pre and post purge the valve is
de-energized (N.C. port closed) and all metered fuel oil
returns to the storage tank. When the valve is energized,
metered oil is directed to the nozzle through the normally
closed port.
NOZZLE ASSEMBLY.
The nozzle assembly consists of four main parts: body,
compression spring, swirler, and tip. The swirler is held
against the nozzle tip by the compression spring. The
nozzle body has inlet ports for air and oil lines. Metered
fuel oil enters the nozzle body and ows 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. Atomizing
air enters and passes through the nozzle body to grooves
in the swirler, where it mixes with fuel oil. Air/oil passes
through grooves and out of the nozzle orice in a cone of
atomized oil. Proper velocity and angle of the ne spray
ensures good mixing with the combustion air, providing
quiet starts and excellent combustion efciency.
D. FLAME SAFEGUARD CONTROLS
The ame safeguard programmer incorporates a ame
sensing cell (scanner) to shut down the burner in the event
of pilot ame or main ame failure. Other safety controls
shut down the burner based on sequence of operation as
shown in the manufacturers ame safeguard manual.
E. COMBUSTION AIR HANDLING SYSTEM
The combustion air handling system consists of two major
components:
1. DAMPER ASSEMBLY.
A multi blade system regulates the combustion air volume
and is positioned by a modulating motor. The dampers are
normally ALMOST CLOSED in the low-re position and
opens as the burner drives toward a high-re position.
2. MOTOR DRIVEN IMPELLER.
The diameter of the impeller determines available air pres-
sure and the width determines air capacity in cubic feet per
minute. Alternate motor-impeller combinations are available
for 50 cycle or 60 cycle power and for ring against either
moderate or high furnace pressure. For higher altitudes and
higher furnace pressures, motor and impeller combinations
are determined at the factory.
F. FIRING RATE CONTROLS
Regardless of the fuel used, burner input is fully modulated
between low re and high re on boiler demand. Firing rate
is controlled by the potentiometer-regulated modulating
motor. Combustion air control damper, oil metering valve
and/or gas volume buttery valves are through variable
rate rod and lever linkages. The modulating motor rotates
90 degrees from low to high position.
Flow rate through each component is adjusted by position-
ing the control rods on the levers and the angular position
of levers on shafts. Lever on the modulating motor shafts
actuate the high re position proving switch.
G. FIRING HEAD
Access to the ring head is provided by swinging open
the impeller housing. First, disconnect the damper linkage,
Figure 1-1
Figure 1-2
PRIMARY GAS
BUTTERFLY VALVE
SECONDARY GAS
BUTTERFLY VALVE
BURNER HEAD ASSEMBLY
WITH DUAL GAS
MANIFOLD
GASKET
REFRACTORY
DRY OVEN
570-057
1-Dual gas manifold
2-Primary gas orifices
3-Secondary gas spuds
4-Diffuser
5-Scanner tube
6-Gas pilot line
7-Pilot
8-Oil Nozzles
9-Oil lines
10-Air atomizing line
1
2
3
4
5
6
7
8
9
10
021-0583

Sec1:5
OIL METERING
The oil metering unit is a MAXON Synchro ow control
valve. The multiple screw cam assembly provides mechani-
cal adjustment capabilities to the fuel ratio at each valve
position throughout the entire capacity range.
OPERATION
Fuel is delivered to the metering system at 50 to 70 psi.
Metered oil is delivered to the common port of a 3-way
solenoid valve for transfer to the burner nozzle through the
normally closed port or back to the storage tank through the
normally open port. During pre- and post purge, metered
oil is returned to the tank. During normal ring, all metered
oil is delivered to the nozzle.
Air enters a rotary vane compressor through an air cleaner
where it is compressed to atomizing pressure. Air ows
from the compressor to an air/oil tank which serves the
multiple purpose of dampening air pulsation, lube oil mist
recovery, lube oil and atomizing air storage. Oil vapor is
extracted by a mist eliminator in the upper section of the
tank. Atomizing air from the upper tank section is delivered
to the nozzle at a constant volume. Air pressure increases
as the burner ring rate increases. Atomizing pressure may
be adjusted by the valve located on the compressor air
breather. The valve allows air to be bled from the tank to
the compressor inlet. Delivery rate of the fuel oil metering
is controlled by the modulating motor through adjustable
linkage.
Figure 1-3
OIL STRAINER
Prevents foreign matter from entering the burner oil
system.
ATOMIZING AIR PROVING SWITCH
Pressure actuated switch contacts close when sufcient
atomizing air pressure is present.The oil valve will not open
unless switch contacts are closed.
SEPARATE COMPRESSOR MODULE
All burners have a burner mounted oil metering unit and
a separate compressor module. The system functions as
follows:
AIR COMPRESSOR MODULE
Air is supplied by a positive displacement rotary vane
compressor. This provides a constant volume of atom-
izing air regardless of pressure. The compressor module
includes motor, air/oil reservoir tank, air lter and lube oil
cooling coil. Air enters the compressor through the lter.
The air ows from the compressor into the air-oil separating
and reservoir tank. Filtering material and bafes separate
the lube oil from the compressed air. The tank air pres-
sure forces lubricating oil from the tank to the compressor
to lubricate bearings and vanes. A sight glass indicates
the level of lubricating oil in the air/oil reservoir. Lubricat-
ing oil must be visible in the gauge glass at all times. Air
compression heat is absorbed in part by the ow of lube
oil, creating a hot oil mist. The air/oil mist is cooled by a
coil assembly. Lube oil is also cooled before entering the
compressor.
VALVE, 1/2" MOTORIZED 3-WAY OIL
VALVE, MAXON FLOW CONTROL
SWITCH, HIGH OIL PRESSURE
VALVE, 1/2" HORIZONTAL CHECK
SWITCH, LOW OIL PRESSURE
GAUGE, 0-60 PSI
VALVE, 1/2" RELIEF
VALVE, 1/2" MOTORIZED 2-WAY
INLET
FROM SUPPLY
REFERENCE:
GAS MANIFOLD
ASSEMBLY
RETURN
TO SUPPLY
METERED OIL
TO NOZZLE

Sec1:6
I. GAS SYSTEM
Gas is introduced into the combustion zone from a
circular manifold through multiple ports in the blast tube,
and through a pre-mix zone. Firing rate is determined by
the size and number of ports, by manifold pressure and by
combustion zone pressure. The ring rate is regulated by
a rotary, buttery type throttling valve at the manifold inlet.
The valve is actuated by an adjustable linkage from the
modulating motor. Depending upon specic requirements,
one or two safety shutoff, motorized main gas valves are
provided for installation in the gas train upstream of the
buttery valves. Safety shutoff gas valves are wired into
the programming control to automatically open and close
at the proper time in the operating sequence.
MAIN GAS TRAIN COMPONENTS
Depending upon the requirements of the regulating au-
thority, the gas control system and gas train may consist
of some, or all, of the following items. A typical gas train
is shown in Figure 1-4.
GAS VOLUME VALVE.
Two buttery type valves are positioned by linkage from the
modulating motor and controls the rate of ow of gas.
MAIN GAS VALVES.
Electrically operated safety shutoff valve(s) that open to
admit gas to the burner. Standard U.L. burners include: One
motorized gas valve w/closure interlock and one standard
motorized valve.
MAIN GAS REGULATOR
Regulates gas train pressure to specied pressure re-
quired at inlet to gas train. Input is set by 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) provides a means of testing for
leakage through the gas valve(s).
HIGH GAS PRESSURE SWITCH.
A pressure actuated switch that remains closed when
gas pressure is below a pre-selected setting. Should the
pressure rise above the setting, the switch contacts will open
causing main gas valve(s) to close. This switch requires
manual reset after being tripped.
LOW GAS PRESSURE SWITCH.
A pressure actuated switch that remains closed when
gas pressure is above a pre-selected setting. Should the
pressure drop below this setting, the switch contacts will
open, causing main gas valve(s) to close. This switch
requires manual reset after being tripped.
PILOT GAS TRAIN
GAS PILOT VALVE.
A solenoid valve that opens during the ignition period to
admit fuel to the pilot. It closes after main ame is estab-
lished.
GAS PRESSURE REGULATOR.
Reduces gas pressure to that required by the pilot.
GAS PILOT SHUT-OFF COCK.
For manually closing the pilot gas supply.
Figure 1-4

Sec1:7
OPERATION
Metered gas ows through the main gas shutoff cock,
through the pressure regulator to the automatic gas valves
and buttery valve to the gas manifold.
The buttery gas valve modulates ow to burner input
demand. The buttery valves are positioned through
mechanical linkage 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. The low and
high gas pressure switches must be closed to prove proper
gas pressure.
A normally open vent valve, if required, is located between
the two automatic gas valves. This valve is shut when
the automatic gas valves are open. When the automatic
valves are closed, the vent valve is open for venting gas
to the outside, should any be present.

Sec1:8
CHAPTER 2
INSTALLATION
supply entrance and pass through the return line and on to
the tank. Metered oil is pumped (by the metering pump) to
the common port of a 3-way valve. With the 3-way valve
de-energized, the metered oil returns to the tank through
the back pressure valve and return line. When the 3-way
valve is energized, metered oil is passed on to the burner
oil nozzle and atomized by air from the compressor. The
proper strainers, check valves, vacuum and pressure
gauges, etc. should be installed as indicated. All lines
should be pressure tested after installation.
F. CIRCULATING OIL PUMP
A circulating oil pump is required to deliver fuel oil from
the storage tank to the burner at a minimum of 150% of
the maximum burner ring rate. The excess oil allows a
margin for piping error, viscosity changes in the fuel oil,
and circulating pump wear. Correct pipe sizing is deter-
mined by circulating rate , not burner capacity. Install the
pump as close to the supply tanks as possible. Suction lift
should be as low as possible. Maximum suction of 15" Hg
vacuum is good practice for either light or heated heavy
oil. The strainer should be installed in the suction line just
ahead of the circulating pump to prevent foreign material
from entering the pump. Locate the strainer so it may be
easily cleaned.
G. OIL PRESSURE REGULATOR
An oil pressure regulator should be installed in the sup-
ply line, close to the burner to regulate oil pressure. Oil
pressure is 50 to 70 PSI to the metering valve.
H. GAS PIPING
Refer to Figures, 2-6 for typical gas piping schemat-
ics.
Gas service and house piping must supply the quantity
of gas demanded by the unit at the pressure required at
the burner gas train inlet. All piping must be in strict accor-
dance with applicable codes, ordinances and regulations of
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 Association (CGA) B149
and Canadian Standards Association (CSA) B140 codes
shall prevail)
Gas train components upstream of the buttery valve
are shipped loose. These components should be mounted
by the installer as close to the buttery valve as practical.
Normally, the control train is ordered to suit a particular code
A. APPLICATION
Electrical power available is usually 230/460 volt, 3
phase, 60 cycle, or 380 volt, 3 phase, 50 cycle. 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. Power connections are made at
the control panel. The burner is furnished with a burner
mounted junction box and remote control panel. Wiring
from the burner junction box to remote panel, panel to boiler
controls, low water controls, remote compressor motor and
remotely located fuel valves is furnished by the installer.
B. INSTALLATION
Locate the burner properly. The burner is designed for
operation with the blast tube level. Do not tilt burner up or
excessively downward. Installation of the refractory oven
or combustion cone, shipped with the burner, is shown in
Figures 2-1 and 2-2. Securely support the burner pedestal
on the oor or foundation. Allow enough clearance at the
rear of the burner to allow the housing to swing open for
service and maintenance. The face of the boiler and burner
ange must be sealed with the gasket provided with the
burner. Carefully place the gasket over the dry oven bolts
before it is mounted onto the burner ange. The I.D. of
the dry oven and burner blast tube are concentric. Due to
bolt hole tolerances, the dry oven may have to be shifted
to accomplish this. After the dry oven nuts are properly
tightened, the burner and dry oven assembly can then be
mounted into the boiler.
C. 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. From inside the furnace,
ram plastic refractory from the front to the rear parallel to
outside surface of the dry oven.
D. SEPARATE COMPRESSOR MODULE
For oil burners supplied with the separate compressor
module, piping to the burner is installed as shown in Figure
2-4. Copper tubing for the installation is not supplied with
the burner.
E. TYPICAL OIL SUPPLY LOOP
Continuous oil circulation must be supplied to the burner
at a rate of 50 percent greater than the high-re burning
rate. The oil circulating pump should be located as close as
possible to the storage tank to keep suction lines short and
minimize suction loss. Note that the supply line is higher
above the burner metering pump inlet to help eliminate air
problems. The return line to the tank is connected at the
discharge port of the 3-way valve. Note that the return line
should be a minimum of 20 inches higher than the supply
line. Since air rises to the highest point, it will rise from the
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.

Sec1:9
1
1
2
2
3
3
4
4
A A
B B
SHEET 1OF 1
INVENTORSCALE: .250:1
DETAILS FOR FIREBOX BOILERS
TITLE
BURNER-MOUNTING, D AND MARC-SERIES
UNLESS OTHERWISE NOTED: FINISH TO BE 120 RMS
INTERPRET PER ASME STANDARDS. OTHER
INDUSTRIAL COMBUSTION ENGINEERING STANDARDS
MAY APPLY.
THIS DRAWING IS A PROPRIETARY ITEM, AND IS THE
PROPERTY OF INDUSTRIAL COMBUSTION. IT IS FOR
INFORMATION ONLY AND CAN NOT BE COPIED OR
USED WITHOUT WRITTEN PERMISSION FROM
INDUSTRIAL COMBUSTION.
R
INDUSTRIAL COMBUSTION, LLC
RELEASE #
DRAWN BY
DATE
REVIEW BY
DATE
-
CLB
THIRD ANGLE PROJECTION
DESIGN UNITS: INCH
TOLERANCES UNLESS NOTED:
NO PLACE
ONE PLACE
TWO PLACE
THREE PLACE
ANGLE
X `.100
.X `.030
.XX `.015
.XXX `.005
X `1°12/18/95
DLP
12/18/95
REV
SIZE
BDRAWING NUMBER 565-00002 A
NOTES
1 - LAY DRY OVEN CONE ON THE FLOOR WITH THE THREADED STUDS UP.
CAREFULLY PRESS THE GASKET OVER THE SUDS.
NOTE: (ONLY THE HOLES FOR THE DRY OVEN CONE ARE PROVIDED)
2 - LIFT THE DRY OVEN CONE ONTO THE BURNER FLANGE AND GENTLY
TIGHTEN THE BOLTS.
3 - MAKE SURE THE DRY OVEN CONE IS CENTERED ON THE BURNER FLANGE
SO THE SPACE IS EQUAL ALL AROUND THE BURNER BLAST TUBE.
4 - MAKE SURE THAT NONE OF THE GASKET IS PROTRUDING INTO THE
AIR STREAM, THEN TIGHTEN THE DRY OVEN CONE NUTS SECURELY.
5 - WRAP THE DRY OVEN CONE WITH TROWLEZE COATED KAO-WOOL
AND LIFT THE BURNER ASSEMBLY ONTO THE BOILER FRONT PLATE
BURNER MOUNTING STUDS AND BOLT SECURELY INTO PLACE.
6 - FINISH REFRACTORY WORK INSIDE FURNACE.
BOILER FRONT PLATE
BURNER MOUNTING FLANGE
(2) 1" INSULATING BLANKETS
(KAO-WOOL, CERABLANKET OR DURABLANKET)
2" BLOCK INSULATION
COAT OUTER CIRCUMFERENCE
OF DRY OVEN CONE WITH TROWLEZE
PACK WITH PLASTIC REFRACTORY
KAISER MONO T-9 AIR SET OR EQUAL
(RAM FROM FRONT TO REAR)
1" GASKET SUPPLIED WITH BURNER
STEEL WRAPPER ON CONE
DRY OVEN CONE SUPPLIED WITH BURNER
WRAP DRY OVEN CONE WITH KAO-WOOL
(COAT BOTH SIDES WITH TROWLEZE)
REV DESCRIPTION RELEASE # DRAWN BY REVIEW BY
AUPDATED TO CURRENT
CAD SOFTWARE -GAS
07/30/08 JCS 07/30/08
45°
MIN
FIREBRICK
1
1
2
2
3
3
4
4
A A
B B
SHEET 1OF 1
INVENTORSCALE: .250:1
DETAILS FOR SCOTCH MARINE BOILERS
TITLE
BURNER-MOUNTING, D AND MARC-SERIES
UNLESS OTHERWISE NOTED: FINISH TO BE 120 RMS
INTERPRET PER ASME STANDARDS. OTHER
INDUSTRIAL COMBUSTION ENGINEERING STANDARDS
MAY APPLY.
THIS DRAWING IS A PROPRIETARY ITEM, AND IS THE
PROPERTY OF INDUSTRIAL COMBUSTION. IT IS FOR
INFORMATION ONLY AND CAN NOT BE COPIED OR
USED WITHOUT WRITTEN PERMISSION FROM
INDUSTRIAL COMBUSTION.
R
INDUSTRIAL COMBUSTION , LLC
RELEASE #
DRAWN BY
DATE
REVIEW BY
DATE
-
CLB
THIRD ANGLE PROJECTION
DESIGN UNITS: INCH
TOLERANCES UNLESS NOTED:
NO PLACE
ONE PLACE
TWO PLACE
THREE PLACE
ANGLE
X `.100
.X `.030
.XX `.015
.XXX `.005
X `1°12/18/95
DLP
12/18/95
REV
SIZE
BDRAWING NUMBER 565-00003 A
NOTES
1 - LAY DRY OVEN CONE ON THE FLOOR WITH THE THREADED STUDS UP.
CAREFULLY PRESS THE GASKET OVER THE SUDS.
NOTE: (ONLY THE HOLES FOR THE DRY OVEN CONE ARE PROVIDED)
2 - LIFT THE DRY OVEN CONE ONTO THE BURNER FLANGE AND GENTLY
TIGHTEN THE BOLTS.
3 - MAKE SURE THE DRY OVEN CONE IS CENTERED ON THE BURNER FLANGE
SO THE SPACE IS EQUAL ALL AROUND THE BURNER BLAST TUBE.
4 - MAKE SURE THAT NONE OF THE GASKET IS PROTRUDING INTO THE
AIR STREAM, THEN TIGHTEN THE DRY OVEN CONE NUTS SECURELY.
5 - WRAP THE DRY OVEN CONE WITH TROWLEZE COATED KAO-WOOL
AND LIFT THE BURNER ASSEMBLY ONTO THE BOILER FRONT PLATE
BURNER MOUNTING STUDS AND BOLT SECURELY INTO PLACE.
6 - FINISH REFRACTORY WORK INSIDE FURNACE.
7 ALL SCOTCH BOILER REFRACTORY PROTECTION MUST EXTEND AT
LEAST 2.5" PAST THE TUBE SHEET.
BOILER FRONT PLATE
BURNER MOUNTING FLANGE
2.5" MINIMUM
TUBE
SHEET
(2) 1" INSULATING BLANKETS
(KAO-WOOL, CERABLANKET OR DURABLANKET)
2" BLOCK INSULATION
COAT OUTER CIRCUMFERENCE
OF DRY OVEN CONE WITH TROWLEZE
PACK WITH PLASTIC REFRACTORY
KAISER MONO T-9 AIR SET OR EQUAL
(RAM FROM FRONT TO REAR)
1" GASKET SUPPLIED WITH BURNER
STEEL WRAPPER ON CONE
DRY OVEN CONE SUPPLIED WITH BURNER
WRAP DRY OVEN CONE WITH KAO-WOOL
(COAT BOTH SIDES WITH TROWLEZE)
45°
MIN
7
REV DESCRIPTION RELEASE # DRAWN BY REVIEW BY
AUPDATED TO CURRENT
CAD SOFTWARE -GAS
07/30/08 JCS 07/30/08
Figure 2-1
Figure 2-2
NOTES:
1. LAY THE DRY OVEN ON THE FLOOR WITH THE STUDS UP. CAREFULLY PRESS THE GASKET OVER THE STUDS.
2. LIFT THE DRY OVEN ONTO THE BURNER FLANGE AND GENTLY TIGHTEN THE BOLTS.
3. MAKE SURE THE DRY OVEN IS CENTERED ON THE BURNER FLANGE SO THE SPACE IS EQUAL ALL AROUND THE BURNER BLAST TUBE
4. MAKE SURE THAT NONE OF THE GASKET IS PROTRUDING INTO THE AIR STREAM. TIGHTEN THE DRY OVEN NUTS.
5. WRAP THE DRY OVEN WITH TROWLEZE COATED KAO-WOOL AND LIFT THE BURNER ONTO THE BURNER STUDS AND BOLT SECURELY IN PLACE.
6. FINISH REFRACTORY WORK INSIDE FURNACE.
NOTES:
1. LAY THE DRY OVEN ON THE FLOOR WITH THE STUDS UP. CAREFULLY PRESS THE GASKET OVER THE STUDS.
2. LIFT THE DRY OVEN ONTO THE BURNER FLANGE AND GENTLY TIGHTEN THE BOLTS.
3. MAKE SURE THE DRY OVEN IS CENTERED ON THE BURNER FLANGE SO THE SPACE IS EQUAL ALL AROUND THE BURNER BLAST TUBE
4. MAKE SURE THAT NONE OF THE GASKET IS PROTRUDING INTO THE AIR STREAM. TIGHTEN THE DRY OVEN NUTS.
5. WRAP THE DRY OVEN WITH TROWLEZE COATED KAO-WOOL AND LIFT THE BURNER ONTO THE BURNER STUDS AND BOLT SECURELY IN PLACE.
6. FINISH REFRACTORY WORK INSIDE FURNACE.
BURNER MOUNTING DETAILS FOR WATERTUBE BOILERS
BURNER MOUNTING DETAILS FOR SCOTCH MARINE BOILERS

Sec1:10
Figure 2-3
or insurance regulation - such as Underwriters Laboratories
, Inc., CGA, Factory Mutual, or Industrial Risk Insurance.
Arrange gas piping at the burner so that the burner is
accessible for servicing without disassembly.
The gas pilot supply line must be connected upstream
of the main gas regulator. If a reducing bushing is required
between the house piping and the burner piping, it should
be close to the burner shut-off valve.
The gas piping must be internally clean and free of
foreign material. Before using in service, a leak test must
be performed.
I. INSTALLATION CHECKLIST
All burners are carefully assembled and tested at the
factory, but before being placed in service, all connectors
should again be checked for looseness caused during
shipment.
Check:
1. Electrical terminals in the control panel and on
all electrical components.
2. Pipe ttings and unions.
3. Tubing connections.
4. Nuts, bolts, screws.
Before operating pumps, metering heads and compres-
sors, make certain that reservoirs are properly lled with
the specic lubricant. Open all necessary oil shut-off
valves. Do not run compressors, pumps, or metering
units without oil.
Before connecting electrical current to any component,
be sure the supply voltage is the same as that specied
on component nameplates.
Before burner operation, be sure all motors are rotating
in the correct direction. See Motor Rotation Reference on
Sec1:13.
Before ring, make sure that the refractory ame cone
is properly sealed to the burner mounting ange and the
boiler front plate.
Make certain that the operator in charge is properly
instructed in the operation and maintenance procedures.
570-071
ATOMIZING
AIR TO
NOZZLE
RADIATOR
R
ELECTRICAL
JUNCTION
BOX
COMPRESSOR BASE
BELT
GUARD
ASSY.
AIR
BREATHER
SIGHT
GLASS
OIL FILTER
MOTORCOMPRESSOR
OIL/AIR
TANK
THE BURNER REFRACTORY CONE IS AIR-CURED
ONLY. HEAT-CURING MUST BE INITIATED AT
INITIAL START-UP. RUN THE BURNER AT LOW
FIRE FOR A PERIOD OF 6 TO 8 HOURS BEFORE
STARTING TO GRADUALY INCREASE THE FIRING
RATE. FAILURE TO DO SO WILL RESULT IN
DAMAGE AND CRACKS IN THE REFRACTORY.
CAUTION

Sec1:11
Figure 2-5
570-070
PRESSURE
REDUCING
STATION
PRESSURE
RELIEF
VALVE
CHECK
VALVE
2-WAY VALVE
(ON BURNER)
H.O.P.S.
L.O.P.S.
NO. 2 OIL PIPING ARRANGEMENT
RETURN SUCTION
CHECK
VALVE
3-WAY VALVE
(ON BURNER)
OIL METER
(SUPPLIED
WITH BURNER)
PRESSURE
GAUGE &
NEEDLE
VALVE
CHECK
VALVE
VACUUM
GAUGE
STRAINER
GATE
VALVE
GATE
VALVE
GATE
VALVE
PIPING BY OTHERS
PIPING BY CB PROFIRE
OIL
CIRCULATING
PUMP
OIL
STORAGE
TANK
TO DRAWER
ASSEMBLY
570-072
1
3
4
PIPING LEGEND
ATOMIZING
AIR INTERLOCK
SWITCH
BURNER
FROM
STORAGE
TANK
RETURN TO
STORAGE
TANK
2
AIR/LUBE OIL
COMPRESSOR MODULE
1. ATOMIZING AIR PRESS. GAUGE
(SUGGESTED LOCATION)
2. OIL-AIR TANK
3. OIL PIPING
4. BURNER NOZZLE ASSEMBLY
FUEL OIL
ATOMIZING AIR
LUBE OIL
Figure 2-4

Sec1:12
B
A
1) NORMALLY OPEN VENT VALVE LINE
SHALL BE HALF OF THE MAIN GAS
TRAIN PIPING SIZE. (3/4" MIN.)
1) FULL SIZE (1/4" OR LARGER) PIPE TO
BE RUN FROM THE VENT OPENING TO
OUTSIDE OF BUILDING.
2) NO TRAPS ALLOWED IN VENT LINE.
3) VENT LINE SHALL TERMINATE AWAY FROM
ALL DOORS AND WINDOWS.
4) PROVISIONS SHALL BE MADE TO PREVENT
FOREIGN OBJECTS FROM ENTERING
VENT PIPING.
AREGULATOR
SHUTOFF
COCK
HIGH GAS
PRESSURE
SWITCH A
Maxon
Maxon
570-0076
B
PILOT
VALVE
PILOT
SHUTOFF
COCK
TEST
OPENING
TYPICAL
REGULATOR
N.O.
VENT
VALVE
MAIN GAS
VALVE
W/P.O.C.
MAIN GAS
VALVE
SHUTOFF
COCK
LOW GAS
PRESSURE
SWITCH
A
A
Figure 2-6
BURNER MOUNTING DETAILS FOR SCOTCH MARINE BOILERS

Sec1:13
S1-SERIES DIMENSION DIAGRAM
R
GENERAL DIMENSIONS
570-096
16-1/8
28
GAS TRAIN CONNECTION
FROM EITHER SIDE
16-3/4
OIL
INLET
55-3/8
23-1/2
103-3/4 R
72-1/2
41-1/4
64-3/4
106-1/2
21-1/8
34
OIL
INLET 16-1/4
(12) HOLES 3/4" DIA.
EQUALLY SPACED AS SHOWN
ON A 45" DIA. B.C.
NOTE:
THESE DIMENSIONS ARE FOR REFERENCE
ONLY. SPECIFICATIONS AND DIMENSIONS
ARE SUBJECT TO CHANGE WITHOUT NOTICE.
AIR OUTLET
1" NPT
48
GAS PILOT
INLET
6-1/4
10-5/8
3-7/8
OIL
RETURN
MAIN GAS
INLET
38-5/8
36-7/8
13-1/4
20-1/4
OIL INLET
1" NPT
23-7/8
21
11-3/4
35-1/237
OIL RETURN
1-1/4" NPT
23-1/8
40-5/8
22-1/2
7-3/8
4 3/8
ELECTRICAL
JUNCTION BOX
39-5/8
ADJUSTABLE BURNER SUPPORT
(5" WHEEL ASSEMBLY)
L
HINGE C
19-3/4
HINGE C 20
L
MAIN GAS
INLET 4" NPT
GAS PILOT
INLET
1/2" NPT
47
16-3/8 R
R
LNS1-SERIES DIMENSION DIAGRAM (BOTTOM ACCESS)
GENERAL DIMENSIONS
69 35
45-1/2
16-1/8
28
21-1/8
34
AIR OUTLET
1" NPT
48
570-097
16-3/8 R
47
GAS PILOT
INLET
1/2" NPT
MAIN GAS
INLET 4" NPT
L20
HINGE C 19-3/4 HINGE C L
ADJUSTABLE
BURNER SUPPORT
(5" WHEEL ASSEMBLY)
39-5/8
ELECTRICAL
JUNCTION BOX
4 3/8
7-3/8
22-1/2
40-5/8
23-1/8
OIL RETURN
1-1/4" NPT
37 35-1/2
11-3/4
21
23-7/8
OIL INLET
1" NPT
20-1/4
13-1/4
36-7/8
38-5/8
MAIN GAS
INLET
OIL
RETURN
3-7/8
10-5/8
6-1/4
GAS PILOT
INLET
NOTE:
THESE DIMENSIONS ARE FOR REFERENCE
ONLY. SPECIFICATIONS AND DIMENSIONS
ARE SUBJECT TO CHANGE WITHOUT NOTICE.
(12) HOLES 3/4" DIA.
EQUALLY SPACED AS SHOWN
ON A 45" DIA. B.C.
16-1/4
106-1/2
72-1/2
103-3/4 R
23-1/2
55-3/8
79-3/4
OIL
INLET
36-1/2
F.G.R. INLET
CONNECTION
F.G.R. INLET
13-1/4" ID. x 21" OD.
(12) TAPPED HOLES 1/2-13 UNC.
EQUALLY SPACED AS SHOWN ON
A 18-3/4" DIA. B.C.
GAS TRAIN CONNECTION
FROM EITHER SIDE
OIL
INLET
16-3/4
Figure 2-7
Figure 2-8

Sec1:14
Figure 2-9
R
LNS1-SERIES DIMENSION DIAGRAM (BOTTOM ACCESS)
GENERAL DIMENSIONS
69 35
45-1/2
16-1/8
28
21-1/8
34
AIR OUTLET
1" NPT
48
570-097
16-3/8 R
47
GAS PILOT
INLET
1/2" NPT
MAIN GAS
INLET 4" NPT
L20
HINGE C 19-3/4 HINGE C L
ADJUSTABLE
BURNER SUPPORT
(5" WHEEL ASSEMBLY)
39-5/8
ELECTRICAL
JUNCTION BOX
4 3/8
7-3/8
22-1/2
40-5/8
23-1/8
OIL RETURN
1-1/4" NPT
37 35-1/2
11-3/4
21
23-7/8
OIL INLET
1" NPT
20-1/4
13-1/4
36-7/8
38-5/8
MAIN GAS
INLET
OIL
RETURN
3-7/8
10-5/8
6-1/4
GAS PILOT
INLET
NOTE:
THESE DIMENSIONS ARE FOR REFERENCE
ONLY. SPECIFICATIONS AND DIMENSIONS
ARE SUBJECT TO CHANGE WITHOUT NOTICE.
(12) HOLES 3/4" DIA.
EQUALLY SPACED AS SHOWN
ON A 45" DIA. B.C.
16-1/4
106-1/2
72-1/2
103-3/4 R
23-1/2
55-3/8
79-3/4
OIL
INLET
36-1/2
F.G.R. INLET
CONNECTION
F.G.R. INLET
13-1/4" ID. x 21" OD.
(12) TAPPED HOLES 1/2-13 UNC.
EQUALLY SPACED AS SHOWN ON
A 18-3/4" DIA. B.C.
GAS TRAIN CONNECTION
FROM EITHER SIDE
OIL
INLET
16-3/4
BURNER AIR
IMPELLER
AIR
COMPRESSOR
MOTOR ROTATION, COUNTER CLOCKWISE REFERENCE
570-0075
ROTATION IS DETERMINED BY FACING THE REAR OF THE MOTOR
MOTOR ROTATION, COUNTER CLOCKWISE REFERENCE
ROTATION IS DETERMINED BY FACING THE REAR OF THE MOTOR
REAR
R
REAR
Figure 2-10

Sec1:15
LUBRICATING OIL IS DRAINED FROM THE
AIR OIL TANK BEFORE SHIPMENT.
BEFORE ATTEMPTING TO START THE
BURNER, ADD OIL TO THE RECOM-
MENDED LEVEL .
CAUTION
CAUTION
BEFORE OPENING THE GAS SHUT-OFF
VALVES, READ THE REGULATOR IN-
STRUCTIONS CAREFULLY. OPEN SHUT-
OFF VALVE SLOWLY TO ALLOW INLET
PRESSURE TO BUILD-UP SLOWLY IN THE
REGULATOR UNTIL IT IS FULLY PRESSUR-
IZED. OPENING THE SHUT-OFF VALVE
QUICKLY WILL DAMAGE THE REGULATOR.
DO NOT EXCEED THE REGULATOR PRES-
SURE RATINGS.