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