CleaverBrooks ProFire D Series Guide

Manual Part No. 750-204 07/2019
ProFire D/LND
Burners
Gas/Oil/Dual Fuel
Installation, Operation, Service, and Parts
Table Of Contents

PROFIRE D/LND
Installation, Operation, and Service Manual
Manual Number: 750-204
Release Date: July 2019

Copyright © 2019 by Cleaver-Brooks
All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means without the prior written consent of Cleaver-Brooks.
Cleaver-Brooks
351 21st Street
Monroe, WI 53566
608-325-3141
www.cleaverbrooks.com

PREFACE
Warning and caution references have been made in this manual and should be adhered to for smooth
operation of the burner.
Model designations are based on the type of fuel(s) to be fired and the amount of furnace pressure to
be overcome. Burner size is based on firing rate (rated input in Btu/hr).
S-Models for up to 1.5” W.C. furnace pressure.
P-Models for up to 4.0” W.C. furnace pressure.
Example: The model number on the nameplate is DLG-252, No. 2 oil and gas burner with input
rated at 25,200 MBtu per hour, against furnace pressures up to 4” W.C. at 60hz.
The installation of a burner shall be in accordance with the regulations of authorities having jurisdic-
tion. The equipment must be installed in accordance with applicable local, state, or provincial instal-
lation 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 equip-
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.
NOTE: This symbol precedes information which is vital to the operation or maintenance of the burner.
Model Standards Fuel-Air Atomization
DG Gas
DL #2 Oil
DLG #2 Oil and Gas
DM #2-5 Oil
DMG #2-5 Oil and Gas
DE #2-6 Oil
DEG #2-6 Oil and Gas
NOTE: Firing at higher furnace pressures de-rates the burner by approximately 5% per one half inch of
additional pressure. Consult with the factory.
!Warning
!Caution

ment shall be connected to flues having sufficient draft at all times to assure safe and proper opera-
tion of the burner.
The D 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, crankcase oil, or any oil containing gasoline.
Gas input based on natural gass at 1,000 Btu/cu. ft. and 0.60 specific gravity.
Burner Size Max. Burner Gas Input MBTU/hr.
60hz 50hz
42 (S or P) 4,200 3,360
54 (S or P) 5,400 4,200
63 (S or P) 6,300 5,250
84 (S or P) 8,400 6,300
105 (S or P) 10,500 8,400
145 (S or P) 14,500 10,500
175 (S or P) 17,500 14,700
210 (S or P) 21,000 16,800
252 (S or P) 25,200 21,000
300 (S or P) 30,000 25,200
315 (P) 31,500 30,000
336 (P) 33,600 31,500
378 (P) 37,800 33,600
420 (P) 42,000 37,800

Oil input based on No. 2 oil at 140,000 Btu/gal.
Burner Size Max. Burner Oil Input U.S.G.P.H.
60hz 50hz
42 (S or P) 30 24
54 (S or P) 39 30
63 (S or P) 47 38
84 (S or P) 60 53
105 (S or P) 75 60
145 (S or P) 107 90
175 (S or P) 125 105
210 (S or P) 150 120
252 (S or P) 180 150
300 (S or P) 215 180
315 (P) 225 215
336 (P) 240 225
378 (P) 270 240
420 (P) 300 270

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Profire D/LND
Table of Contents
CHAPTER 1 Introduction 1-1
1.1 — Overview 1-1
1.2 — Description 1-1
1.3 — Operating Controls 1-2
1.4 — Flame Safeguard Controls 1-2
1.5 — Combustion Air Handling System 1-3
1.6 — Firing Rate Controls 1-3
1.7 — Firing Head 1-4
1.8 — Oil System Air Atomizing 1-5
1.8.1 — 3-Way Solenoid Valve 1-5
1.8.2 — Nozzle Assembly 1-5
1.8.3 — Burner Mounted Trim Heater 1-6
1.8.4 — Oil Strainer 1-6
1.8.5 — Atomizing Air Proving Switch 1-6
1.8.6 — Air/Lube Oil Tank 1-6
1.8.7 — Integral Air/Oil Unit 1-6
1.8.9 — Air Compressor 1-7
1.8.10 — Oil Metering 1-7
1.8.11 — Separate Compressor Module 1-7
1.9 — Gas System 1-10
1.9.1 — Main Gas Train Components 1-11
1.9.2 — Pilot Gas Train Components 1-12
1.9.3 — Operation 1-12
CHAPTER 2 Installation 2-1
2.1 — Application 2-1

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2.2 — Combustion Chamber Construction 2-1
2.3 — Installation 2-4
2.4 — Packing Plastic Refractory Around Oven 2-5
2.5 — Separate Compressor Module 2-5
2.6 — Typical Oil Supply Loop 2-6
2.7 — Oil Circulating Loop Operation 2-7
2.8 — Circulating Oil Pump 2-8
2.9 — Oil Loop Heater 2-8
2.10 — Burner Mounted Trim Heater 2-8
2.11 — Back Pressure Valve 2-8
2.12 — Gas Piping 2-9
2.13 — Installation Checklist 2-9
CHAPTER 3 Operation 3-1
3.1 — Preparations for Starting 3-1
3.1.1 — Oil Flow 3-2
3.1.2 — Oil Pressure 3-2
3.1.3 — Oil Temperature 3-2
3.1.4 — Air-Oil Tank (Lube Oil) 3-3
3.1.5 — Firing Preparations for Gas Burners 3-3
3.2 — Electrical Interference Test 3-3
3.2.1 — Gas Fired 3-3
3.2.2 — Oil Fired 3-3
3.3 — Gas Pilot Flame Adjustment 3-4

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3.4 — Startup Sequence 3-4
3.5 — Automatic Shutdown 3-5
3.6 — Manual Shutdown 3-5
3.7 — Safety Shutdown 3-5
3.8 — Startup and Operating 3-6
3.8.1 — Gas Burners 3-6
3.8.2 — Oil Burners 3-6
3.9 — Normal Operation 3-7
3.10 — Shutdown 3-7
CHAPTER 4 Adjustments 4-1
4.1 — Overview 4-1
4.2 — Combustion Adjustment on Gas and Oil 4-1
4.2.1 — Stack Temperature 4-1
4.2.2 — Smoke Measurement 4-2
4.2.3 — Gas Adjustments 4-2
4.2.4 — Fuel Oil Adjustments 4-2
4.3 — Electrical Interference Test 4-2
4.3.1 — Gas Fired 4-2
4.3.2 — Oil Fired 4-2
4.4 — Gas System 4-3
4.4.1 — Gas Pressure 4-3
4.4.2 — Gas Flow 4-3
4.4.3 — Gas Pilot Flame Adjustment 4-3
4.4.4 — Main Gas Pressure Regulator 4-3
4.4.5 — Low Gas Pressure Switch 4-3
4.4.6 — High Gas Pressure Switch 4-4
4.4.7 — Gas Combustion Adjustment 4-4
4.4.8 — Secondary Valve Adjustment: Gas Models D 378 & 420 4-4
4.4.9 — Secondary Valve Adjustment: Dual Manifold 4-5

iv 750-204
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4.5 — Oil System 4-5
4.5.1 — Oil Metering System 4-5
4.5.2 — Atomizing Air Pressure 4-6
4.5.3 — Atomizing Air Proving Switch 4-6
4.5.4 — Low Oil Pressure Switch 4-6
4.5.5 — High Oil Temperature Switch 4-6
4.5.6 — Nozzle Line Heater 4-7
4.6 — Linkage: Modulating Motor 4-7
4.7 — Cam Trim Adjustment 4-9
4.8 — Firing Rate Controls 4-9
5.11.4 — Air-Oil Tank 5-7
5.11.5 — Oil Level Sight Gauge 5-7
5.11.6 — Compressor Oil Filter (Lube Oil Strainer) 5-7
5.11.7 — Oil Strainers 5-7
CHAPTER 5 Maintenance 5-1
5.1 — Overview 5-1
5.2 — Control System 5-1
5.2.1 — Programming Control 5-2
5.3 — Impeller and Stator Cone 5-2
5.4 — Firing Head Inspection 5-2
5.5 — Pilot and Ignition Electrode 5-4
5.6 — Flame Scanner 5-4
5.7 — Oil Nozzle 5-4
5.8 — Diffuser 5-6
5.9 — Firing Rate Controls 5-6
5.10 — Burner Mounting Inspection 5-6

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5.11 — Fuel Oil System 5-7
5.11.1 — Fuel Oil Circulating Pump 5-7
5.11.2 — Air-Oil Metering Pump 5-7
5.11.3 — Primary Air Pump or Compressor 5-8
5.11.4 — Air Cleaner 5-8
5.11.5 — Air-Oil Tank 5-8
5.11.6 — Oil Level Sight Gauge 5-8
5.11.7 — Compressor Oil Filter (Lube Oil Strainer) 5-8
5.11.8 — Nozzle Line Heater 5-9
5.11.9 — Oil Strainers 5-9
5.12 — Gas System 5-9
5.12.1 — Motorized Main Gas Valves 5-9
5.12.2 — Solenoid Valves 5-9
5.13 — Electrical System 5-10
5.13.1 — Electric Motors 5-1
0
5.14 — Extended Shutdown 5-10
5.15 — Maintenance Flow Chart Recommended Test Schedule 5-11
CHAPTER 6 Troubleshooting 6-1
6.1 — Awareness 6-1
6.2 — Emergency Shutdown 6-2
6.3 — Troubleshooting 6-3
CHAPTER 7 Accessories 7-1
7.1 — Overview 7-1
7.2 — Steam Atomizing System 7-1
7.3 — Air Purge System (optional) 7-2
7.4 — Plant Air System 7-2

vi 750-204
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CHAPTER 8 Flue Gas Recirculation 8-1
8.1 — LN Model Designations, Sizes, and Inputs 8-1
8.2 — Description 8-3
8.3 — FGR Shutoff Valve 8-4
8.4 — FGR Control Valve 8-5
8.5 — Air/FGR Damper Assembly 8-5
8.6 — Blast Tube Temperature Interlock (optional) 8-7
8.7 — Stack Temperature Interlock (optional) 8-7
8.8 — 20 PPM Design 8-7
CHAPTER 9 Parts Lists and Drawings 9-1
9.1 — Instructions 9-1
9.2 — Parts Shipping Policy 9-1
9.3 — Return Goods Procedures (Credit or Replacement Parts) 9-2
9.4 — Parts Lists and Drawings 9-4
9.4.2 — Blast Tube Assembly D42 - 336 9-4
9.4.2 — Blast Tube Assembly D378 - 420 9-6
9.4.3 — Blower Housing Assembly D42 - 175 9-8
9.4.4 — Blower Housing Assembly D210 - 336 9-10
9.4.5 — Blower Housing Assembly D378 - 420 9-12
9.4.6 — Compressor Set D42 - 145 9-14
9.4.7 — Compressor Set D175 - 336 9-16
9.4.8 — Compressor Set D378 - 420 9-18
9.4.9 — Control Package, Fireye 9-20
9.4.10 — Control Package, Honeywell 9-22
9.4.11 — Damper Assembly D42 - 420 9-24
9.4.12 — Damper Assembly LND42 - 420 9-26
9.4.13 — Drawer Assembly D42 - 63 9-28
9.4.14 — Drawer Assembly D84 - 145 9-30
9.4.15 — Drawer Assembly D175 - 336 9-32

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9.4.16 — Drawer Assembly D378 - 420 9-34
9.4.17 — Firing Head Assembly D42 - 420 9-36
9.4.18 — Oil Air Tank DL, DM42 - 145 9-38
9.4.19 — Oil Heater D42 -420 9-39
9.4.20 — Oil Metering Assembly DL, DLG, DM, DMG42 - 145 9-41
9.4.21 — Oil Metering Assembly DL, DLG, DM, DMG175-420 & DE, DEG42 - 420 9-43
9.4.22 — Oil Metering Assembly D378 - 420 9-46
9.4.23 — Modulation, Standard 9-48
9.4.24 — Modulation, Standard Low NOx or Left Hand Gas 9-49
9.4.25 — Modulation, Cam Trim 9-50
9.4.26 — Modulation, Cam Trim Low NOx or Left Hand Gas 9-52
STARTUP/SERVICE REPORT
WARRANTY POLICY

viii 750-204
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750-204
Profire D/LND 1-1
CHAPTER 1 Introduction
1.1 — Overview
Profire D/Series burners are assembled, wired, and tested at the factory. They are listed by the Underwriters Lab-
oratory, CSD-1, NFPA-85, I.R.I., F.M., including the National electrical Code (NEC) and associated insurance
underwriters. Where applicable, the Canadian Gas Association (CGA) B149 and Canadian Standards Association
(CSA) B140 codes shall prevail. Other regulatory agency control options are available.
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.
1.2 — Description
The Profire D/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 flame. With either fuel, the burner
operates with full modulation. A switch permits changeover from automatic fully modulated firing to manually set
firing at any desired rate between minimum and maximum. Additional safeguards assure that the burner always
returns to minimum firing position for ignition.
D/Series burners are designed for automatic, unattended operation except for periodic inspection and mainte-
nance. After selecting the proper overload settings for the starter, the rest of the control panel components
require little attention except for occasional cleaning.
Only factory authorized burner service personnel should start-up, adjust, or service this equipment.
!Caution

Introduction
1-2 750-204
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1.3 — Operating Controls
The control panel contains a flame safeguard programming control, motor starters, relays, time delays, and ter-
minal strips mounted internally on a panel subbase. Lights, switches, potentiometers, a control circuit breaker,
and flame safeguard displays are mounted externally on the panel as indicated:
1.4 — Flame Safeguard Controls
The flame safeguard programmer incorporates a flame sensing cell (scanner) to shut down the burner in the
event of pilot flame or main flame failure. Other safety controls shut down the burner based on sequence of oper-
ation as shown in the manufacturer’s flame safeguard manual.
Component Details
On-Off Burner Switch For gas or oil only.
Fuel Selector Switch Gas-Off-Oil
For combination gas-oil burners only.
a) Gas Position: Selects gas as the firing fuel.
b) Off Position: Burner off.
c) Oil Position: Selects oil as the firing fuel.
NOTE: When changing from oil to gas fuel, allow the programmer to com-
plete post-purge and shutdown before moving the selector switch to the gas
position. This will allow the interlock circuit to de-energize at either the oil-
air pump or the compressor.
Control Circuit Breaker Supplementary low overcurrent protection only. No larger than 15 amps.
Auto-Manual Modulation Selector
Switch
a) Auto Position: Selects boiler modulation control.
b) Manual Position: Selects 135 ohm potentiometer for manual modulating
control.
Manual Modulating Control 135 ohm Increases or decreases the burner firing rate manually.
Signal Lamps a) Power On (white): Illuminates when the control circuit is energized (pow-
ered).
b) Ignition (amber): Illuminates when the ignition transformer is powered,
and gas pilot valve is energized (open).
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 flame safeguard system fails to
detect pilot or main flame.
Read the flame safeguard manual and fully understand its contents before attempting to operate this equipment. Fail-
ure to follow this instruction may result in serious personal injury or death.
!Warning

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1-3
1.5 — Combustion Air Handling System
1.5 — Combustion Air Handling System
The combustion air handling system consists of three major components:
FIGURE 1-1. Damper, Impeller, and Stator Cone
1.6 — Firing Rate Controls
Regardless of the fuel used, burner input is fully modulated between low fire and high fire on boiler demand. The
firing rate is controlled by the potentiometer-regulated modulating motor. The combustion air control damper, oil
Component Details
Damper Assembly A rotary damper regulates the combustion air volume and is positioned by a
modulating motor. The damper is normally almost closed in the low fire
position and opens as the burner drives toward a high fire position.
Motor Driven Impeller The diameter of the impeller determines available air pressure 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
firing against either moderate or high furnace pressure. At altitudes up to
2,000 ft. above sea level, model “S” impellers are recommended for up to
1.5” W.C. furnace pressure. Model “P” impellers are recommended for fur-
nace pressures from 1.5” to 4.0” W.C. For higher altitudes and higher fur-
nace pressure, motor and impeller combinations are determined at the
factory.
Stator Cone The stator cone in the air housing transforms the rotating air velocity pres-
sure to static pressure prior to air entry into the blast tube.

Introduction
1-4 750-204
Profire D/LND
metering pump, and/or gas volume butterfly valve are controlled through variable rate rod and lever linkages. The
modulating motor rotates 90º from low to high position. Flow rate through each component is adjusted by posi-
tioning the control rods on the levers and the angular position of levers on shafts. The lever on the modulating
motor shafts actuate the high fire position proving switch.
1.7 — Firing Head
Access to the firing head is provided by swinging open the impeller housing. First, disconnect the damper link-
age, release the housing latch, and swing the housing to the open position. An internal gas pilot is standard on
all burners. Pilot gas pressure is adjusted at the pilot pressure regulator.
FIGURE 1-2. Firing Head Assembly