table of contents -...

Manual Part No. 750-282 12/2009

Profire KBurner

Light Oil, Gas, or Combination

InstallationOperation

Maintenance

Table Of Contents

ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST, OR SERVICE THIS EQUIPMENT.

WARNING

K/SERIESInstallation, Operation,andService Manual

750-28212/09

K SERIES TABLE OF CONTENTS

PAGESECTION 1. INTRODUCTIONA. GENERAL INFORMATION .............................................. 3B. DESCRIPTION ................................................................. 3C. OPERATING CONTROLS ............................................... 3D. FLAME SAFEGUARD CONTROLS ................................. 3E. COMBUSTION AIR HANDLING SYSTEM ....................... 4F. OIL SYSTEM ................................................................... 4G. PILOT SYSTEM ............................................................... 4H. GAS SYSTEM.................................................................. 4

SECTION 2. INSTALLATIONA. DRAFT CONDITIONS .......................................................7B. COMBUSTION AIR SUPPLY ............................................7C. COMBUSTION CHAMBER DESIGN ................................7D. BURNER INSTALLATION .................................................7E. GAS PIPING .................................................................... 9F. FUEL OIL PIPING ............................................................. 9G. INSTALLATION CHECKLIST........................................... 14

SECTION 3. STARTING AND OPERATINGA. PREPARATION FOR INITIAL START-UP ....................... 15B. FIRING PREPARATIONS .............................................. 15C. SEQUENCE OF OPERATION ........................................ 16D. ELECTRICAL INTERFERENCE TEST ........................... 16E. START-UP AND OPERATION ........................................ 17F. NORMAL OPERATION .................................................... 19G. SHUTDOWN .................................................................... 19

SECTION 4. ADJUSTMENTSA. GENERAL ....................................................................... 20B. COMBUSTION ADJUSTMENTS OIL AND GAS ............. 20C. GAS PILOT ADJUSTMENT ............................................ 21D. DIRECT SPARK OIL PILOT ADJUSTMENT ................... 21E. BURNER SETTINGS ...................................................... 21F. PILOT TURN DOWN TEST ............................................. 23G. LOW-HIGH OFF BURNER ADJUSTMENTS ................... 23H. FULL MODULATION BURNER ADJUSTMENTS ........... 25

PAGESECTION 5. MAINTENANCEA. GENERAL ........................................................................ 28B. CONTROL SYSTEM ........................................................ 28C. GAS SYSTEM.................................................................. 28D. OIL SYSTEM ................................................................... 29E. DRAWER ASSEMBLY ..................................................... 29F. IGNITION ELECTRODE, CABLE, AND PILOT ............... 29G. FLAME SCANNER .......................................................... 29H. BURNER MOUNTING INSPECTION .............................. 29 I. EXTENDED SHUTDOWN ................................................ 29J. MAINTENANCE FLOW CHART ...................................... 30

SECTION 6. TROUBLE SHOOTINGBURNER DOES NOT START .............................................. 31NO IGNITION ....................................................................... 31PILOT BUT NO MAIN FLAME .............................................. 32BURNER STAYS IN LOW FIRE ........................................... 32SHUTDOWN DURING FIRING..........................................32-33MODULATING MOTOR DOES NOT OPERATE .................. 33

WARRANTY POLICY........................................................35-36

START-UP AND SERVICE REPORT ................................... 37

PRODUCT SATISFACTION SURVEY ................................. 38

1

OPERATING PRECAUTIONSThis 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 Prof 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:

HAZARD OF ELECTRIC SHOCK !!! MORE THAN ONE DISCONNECT MAY BE RE-QUIRED TO DISCONNECT ALL POWER TO THIS PANEL. SERIOUS PERSONAL INJURY OR DEATH MAY RESULT.

READ PRODUCT MANUAL AND FULLY UNDERSTAND ITS CONTENTS BEFORE-ATTEMPTING TO OPERATE THIS EQUIP-MENT. SERIOUS PERSONAL INJURY OR DEATH MAY RESULT.

TO AVOID PERSONAL INJURY FROM MOVING PARTS, SHUT OFF ALL ELEC-TRICAL POWER BEFORE SER VICING THIS EQUIPMENT.

WARNINGPROVIDE SUPPORT FOR THIS PANEL TO PREVENT DAMAGE TO THE ELEC-TRICAL COMPONENTS.

CAUTION

ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START- UP, ADJUST, OR SERVICE THIS EQUIP-MENT.

CAUTIONAFTER FINAL FUEL INPUT ADJUST-MENTS ARE MADE, VERIFY FUEL IN-PUT BY METER IF POSSIBLE.

CAUTION

WARNING

WARNING

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 PERSONNEL.

2

Model designations are based on the type of fuel(s) to be f red and the amount of furnace pressure to be over-come. Burner size is based on f ring rate (rated input in BTU/HR).

EXAMPLE: Model number on nameplate isKLG-42, indicating it is a combination No. 2 oil and Gas burner with input rated at 4,200 MBTU per hour, against furnace pressures up to 1.0” W.C.

BURNER SIZE AND RATED FURNACE PRESSURE K/BURNER:SIZE 1 - K13 to 25 0.75” W.C.SIZE 2 - K30 to 42 1.5” W.C.SIZE 3 - K54 to 84 3.0” W.C.SIZE 4 - K105 to 145 4.0” W.C.

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.

OIL AND GAS BURNING EQUIPMENTS SHALL BE CONNECTED TO FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES, TO ASSURE SAFE AND PROPER OPERATION OF THE BURNER.

THE K SERIES BURNERS ARE DESIGNED TO BURN EITHER GAS OR LIGHT OIL No.1 OR 2 AS DEFINED BY ASTM D396-1978 SPECIFICATIONS.DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE.

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.

RATED BURNER INPUTSIZE MBTU/HR US GPH

13 1,260 9.0

17 1,680 12.0

21 2,100 15.025 2,520 18.030 2,940 21.034 3,360 24.042 4,200 30.054 5,250 37.563 6,300 45.084 8,400 60.0

105 10,500 75.0125 12,600 90.0145 14,700 105.0

* Gas input based on natural Gas at 1,000 Btu/cu.ft. and 0.60 specif c gravity. ** Oil input based on 140,000 Btu/gal.*** Refer to burner nameplate data for correct manifold pressures.

MODEL FUEL ATOMIZATIONKG GASKL #2 OIL PRESSURE

KLG #2 GAS/OIL PRESSURE

3

A. GENERAL INFORMATION CB Pro f re K/Series burners are assembled, wired and tested at the factory. They are listed by the Underwriters Laboratory, cUL, CSD-1, I.R.I., F.M., and other regulatory agency control options are available.

The operator of this equipment must be familiar with the individual functioning of all controls to understand the operations and procedures described in this manual, and supplementary instructions provided with optional controls. Identify and locate each item in the illustrations as they are described in the following sections.

B. DESCRIPTIONCB Prof re K/Series burners are designed to operate with gas and light oil. K burners are speci f cally designed to operate in scotch marine type boilers. The burners are designed for automatic, unattended operation except for periodic inspection and maintenance. The control panel components require little attention except for occasional cleaning. The burners are available in the following conf guration:

SIZE 1 - K13-25 Low-High-Off(Optional: Low-High-Low, Full Modulation)

SIZE 2 - K30-42 Low-High-Off (Optional: Low-High-Low, Full Modulation)

SIZE 3 - K54-84 Full Modulation

SIZE 4 - K105-145 Full Modulation

C. OPERATING CONTROLS - PANELThe control panel contains a f ame safeguard program-ming control, motor relays (starters), and terminal strips mounted internally on a panel subbase. Lights, switches, and a control circuit breaker are mounted externally on the panel as indicated below.

1. ON-OFF BURNER SWITCH

2. FUEL SELECTOR SWITCH - Gas - Off - Oil

Gas position: Selects gas as the f ring fuel Off position: Burner off Oil position: Selects oil as the f 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. In this position, the burner will operate automatically in response to load demand. Manual Position: Selects 135 ohm potentiometer for manual modulating control.

5. MANUAL MODULATING CONTROL 135 ohm (For full modulation burners only) Increases or decreases the burner f 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 pilot valve is energized (opened). c. MAIN FUEL (green) illuminates when the main fuel valve or valves are energized (open). d. FLAME FAILURE (red) illuminates when the f ame safeguard system fails to detect pilot or main f ame.

7. MODULATING MOTOR Operates the air damper and fuel rate valves through a linkage system to adjust air-fuel ratios under all load conditions.

8. IGNITION TRANSFORMER Provides high voltage spark for ignition of gas pilot or main f ame direct spark models.

D. FLAME SAFEGUARD CONTROLSThe f ame safeguard controls the operating sequence of the combustion system (prepurge, pilot, f ring and shutdown). The f ame safeguard programmer incorporates a f ame sensing cell (scanner) to shut down the burner in the event of pilot f ame or main f ame failure. Other safety controls shut down the burner based on sequence of operation as shown in the manufacturers f ame safeguard manual.

ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START-UP, ADJUST, OR SERVICE THIS EQUIPMENT

CAUTION

SECTION 1INTRODUCTION

4

E. COMBUSTION AIR HANDLING SYSTEM1. MOTOR AND BLOWER - The impeller is directly driven by the motor at 3450 rpm. Combustion air is supplied by a heavy duty balanced backward curved impeller . The impeller remains free from dirt accumulation.

2. AIR VOLUME REGULATOR - The air damper is located in the air inlet housing. Low-high-of f, low-high-low or full modulation burners have the damper directly driven by the modulating motor.

3. COMBUSTION AIR PROVING SWITCH - A pressure sensitive switch actuated by air pressure created by the blower fan. Contacts close to prove combustion air f ow.

OPERATIONAir from the impeller f ows through the blast tube and baff e to mix with fuel in the ignition zone. Combustion air f ow rate is determined by the position of the air regulating blades at the inlet of the impeller. Linking the air f ow with fuel f ow provides eff cient combustion at all f ring rates.

F. OIL SYSTEMModels KL - KLG are high pressure atomizing burners using fuel pressure for atomization. Atomized fuel is discharged from the nozzle as a f ne conical spray.

1. FUEL UNIT - Direct driven from the blower motor with a f exible coupling at 3450 rpm, and set for 300 psi opera-tion, fuel unit is two stage (two sets of gears) and must be installed for a two pipe installation, one suction and one return line. Separately driven oil pumps are available as option to the standard arrangement.

2. NOZZLE - The nozzle meters oil f ow delivering a speci-f ed amount at a specif c pressure. Fuel pressure (mechani-cal) atomizes oil in a f ne conical spray pattern from the nozzle orif ce. The burner is supplied with nozzle(s) to f re to its maximum rate unless a different f ring rate was specif ed. Return f ow nozzle(s) are used on the size - 4 burners.

3. NOZZLE ADAPTOR - The nozzle adaptor provides the means for connecting fuel lines with the nozzle.

4. OIL SOLENOID VALVES - Two normally closed (N.C.) and one normally open (N.O.) solenoid valves are part of the oil system on LO-HI-OFF and LO-HI-LO burners. The two N.C. valves provide positive shut of f of fuel oil while the one N.O. valve cycles the burner to high f re when closed.

5. OIL METERING VALVE - The f ring rate is controlled by an adjustable metering valve in the return line. At low-f re, the metering valve is open, and is closed at high-f re.

6. OIL FILTER - Prevents foreign matter from entering the burner oil system. This item is provided optional and

shipped loose with burner.

OPERATIONFuel oil is delivered to the fuel unit, either by gravity , fuel unit suction, or by a circulating pump, through a fuel oil f lter. Pressurized fuel returns to the storage tank until the two solenoid valves open. On direct spark ignited burners, (KL-13 to 42) ignition occurs when the oil valves open. Where gas pilots are provided (Models KG and KLG), the oil valves open after the pilot is proven. Oil input rate is controlled by the oil metering valve, which varies the f ow to meet load demands. The low-f re positions bypass oil back to the storage tank. At high-f re, the metering valve is in the closed position. The metering valve and the air damper are positioned simultaneously by the modulating motor.

G. PILOT SYSTEMOil only models KL-13 to 42 are supplied with direct spark ignition. Models KL-54 to 145 are supplied with a gas pilot system. Gas and combination Gas-Oil models are supplied with a gas ignition system. The standard pilot gas train consists of a manual shutoff cock, a gas pressure regulator and a solenoid operated gas shutoff valve.

H. GAS HANDLING SYSTEMDepending upon the requirements of the regulating author-ity, the gas control system and gas train may consist of some, or all, of the following items:

MAIN GAS TRAIN COMPONENTS1. GAS VOLUME VALVE - The butterf y type valve is po-sitioned by linkage from the modulating motor and controls the rate of f ow of gas.

2. MAIN GAS VALVES - Electrically operated safety shutoff valve(s) that open to admit gas to the burner . Standard U.L. burners include: -Models: 13-25; Diaphragm gas valve and one safety solenoid valve -Models: 30-42; One motorized gas valve w/proof of closure -Models: 54-145; One motorized gas valve w/proof of closure and one safety solenoid valve

3. MAIN GAS REGULATOR - Regulates gas train pressure to specif ed pressure required at the burner manifold. Input is set by main gas pressure regulator adjustment.

4. MAIN GAS COCKS - Used for manual shutof f 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).

5. HIGH GAS PRESSURE SWITCH. (Models 30-145) A pressure actuated switch that remains closed when gas pressure is below a 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

5

reset after being tripped.

6. LOW GAS PRESSURE SWITCH. (Models 30-145) A pressure actuated switch that remains closed when gas pressure is above a selected setting. Should the pres-sure drop below this setting, the switch contacts will open, causing main gas valve(s) to close. This switch requires manual reset after being tripped.

OPERATION Metered gas f ows through the main gas shutof f cock, through the pressure regulator to the automatic gas valves and butterf y valve to the gas manifold.The butter f y gas valve modulates f ow to burner input demand. The but-terf y valve is 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.

G A S T R A I N C O M P O N E N T S U P -S T R E A M O F T H E B U T T E R F L Y VALVE ARE SHIPPED LOOSE TO BE MOUNTED BY THE INST ALLER.

NOTE

PILOT GAS SUPPLY CONNECTION MUST BE UPSTREAM OF THE MAIN GAS PRES-SURE REGULATOR.

NOTE

Figure 1-1

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.

GAS BUTTERFLYVALVE

COMBUSTION AIR SWITCH

OIL PUMP

MODULATING MOTOR

GAS PILOT LINE

BLOWER MOTOR

IGNITION TRANSFORMER

CONTROL PANEL656-09610

6

NOZZLE BODY & TIP

GAS MANIFOLD

MOUNTING FLANGE

AIR BAFFLE

GAS ORIFICES

Figure 1-2

656-09611

7

SECTION 2INSTALLATION

A. DRAFT CONDITIONS A boiler or other heating vessel f red with a K Series burner does not depend on chimney draft for proper combustion air. Combustion air is supplied by the burner forced draft blower providing adequate air for any normal combustion condition. Since draft control is essential to maximum ef f ciency, a draft regulator may be required when the vessel is con-nected to a tall stack or where wind conditions may cause erratic draft. Excessive furnace draft contributes to ineff cient burner operation. Sealed boilers may be operated under positive f rebox pressure within the capability of the burner.

B. COMBUSTION AIR SUPPLY The space in which a burner operates must be supplied with adequate 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 specif c regulations.

C. COMBUSTION CHAMBER DESIGN Suggested minimum combustion chamber dimensions in Figure 2-1 are based on the rated capacity of the burner. While these dimensions are typical for good practice, satisfactory results may be achieved with modif cations to suit some conditions. Factors such as fuel properties, total combustion volume, and length of f ame travel often make f xed requirements impractical. When in doubt, consult the facotry. Insulation should be provided between the burner mounting f ange and the boiler adaptor plate.

WARNINGTHE BOILER ROOM PRESSURE MUST BE AT LEAST EQUAL TO THE OUTDOOR ATMO-SPHERIC PRESSURE. WHERE FAN VENTILA-TION IS USED, AIR MUST BE FORCED INT O THE BOILER ROOM. NEVER EXHAUST AIR FROM THE BOILER ROOM. ADJOINING AREAS HAVING EXHAUST FANS MUST BE POSITIVILY ISOLATED FROM THE BOILER ROOM.

BURNER COMBUSTION CHAMBERMODEL LENGTH WIDTH CL HEIGHT

13 56 26 1217 56 26 1221 56 26 1225 56 26 1230 62 30 13.534 62 30 13.542 62 30 13.554 83 33 1563 83 33 1584 104 39 18.5105 128 39 18.5125 128 39 18.5145 128 39 18.5

Figure 2-1

GASKET MUST BE RESILIENT TO SEAL ANY UNEVEN AREAS BETWEEN THE BURNER FLANGE AND THE BOILER FRONT PLATE TO PREVENT LEAKAGE OF COMBUSTION GASES.

CAUTION

D. BURNER INSTALLATIONPrepare the boiler front plate as follows:

1. Determine burner mounting height. Locate and scribe a level horizontal centerline across the mounting face.

2. Locate and scribe vertical centerline. Be sure stud loca-tions line up where studs will have full support. If they don’t or if opening is too large, a steel adapter plate, 3/8” mini-mum may be welded or bolted in place. Suitable anchors should be provided to hold refractory in place. Adapter plate must be properly sealed (use insulating rope gasket to prevent leakage of combustion gases.

3. Using insulating rope gasket, wrap rope on the inside of the bolt circle, looping rope around the four mounting studs.

4. Set burner into position for mounting and tighten into place. Size 1, 2 and 3 burners are provided with four lugs to secure burner to front plate. Size 4 burners are equipped with a four hole mounting f ange.

5. Permanently support the burner using the pipe support connections. See Figure 2-2.

6. The space between the boiler refractory, water leg, or f re tube and outside diameter of the blast tube must be packed with plastic refractory, Kaiser Refractory Mono T-Air Set or equal. Ram plastic refractory from front to rear, parallel to outside surface of blast tube. See Figure 2-3.

8

SUPPORT BURNER HERE

Figure 2-2

(2) 1" INSULATING BLANKET(KAO-WOOL, CERABLANKET, DURABLANKET)

BURNER HEAD

ON ALL SCOTCH BOILERS REFRACTORYPROTECTION MUST EXTEND AT LEAST2.50" PAST THE TUBE SHEETTUBE

SHEET

2" BLOCK INSULATION

2.50" MIN.

PACK WITH PLASTIC REFRACTORY(KAISER MONO T-9 AIR SET OREQUAL, RAM FROM FRONT TO REAR)

WRAP WITH KAO-WOOL (COAT BOTH SIDES WITH TROWLEZE)

45°

BOILER FRONT PLATE

BURNER FLANGE

MIN.

1" GASKET OR ROPE

BURNER MOUNTING DETAILS FOR SCOTCH MARINE BOILERS

Figure 2-3

9

E. GAS PIPING 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 accordance with applicable codes, ordinances and regulations of the supplying utility. In the absence of other codes, piping should be in accor-dance with the following standards: ”National Fuel Gas Code” NFPA No. 54, ANSI No. Z223-1.

Gas train components upstream of the butterf y valve are shipped loose. These components should be mounted by the installer as close to the butterf y valve as practical.

Normally, the control train is ordered to suit a particular code or insurance regulation - such as Underwriters Labo-ratories / Canadian Underwriter’s Laboratories (UL / cUL) Factory Mutual, or Industrial Risk Insurance. See Figure 2-4 through 2-6 for component arrangement. Arrange gas piping at the burner so that the burner is accessible for servicing without disassembly.

The pilot gas train is supplied with the burner, and is fac-tory installed. 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 shutoff valve.

The gas piping must be internally clean and free of for-eign material. Before using in service, a leak test must be performed. (SEE SECTION 3-E)

F. FUEL OIL PIPING

PRESSURE ATOMIZATION OIL PIPINGThe KL and KLG model burners use pressure atomization. Fuel oil is provided by a burner mounted fuel unit directly coupled to the blower motor via a f exible coupling. The suction and return line sizes (two-pipe system) are based on the suction rate of the fuel unit and not the burner f ring rate. Pipe size must be selected so that suction vacuum is within suitable limits.

TWO PIPE - SINGLE BURNER OPERATION. A two-pipe system is essential. The suction and return between the storage tank or supply source and the burner must be sized to supply the required quantity of oil circulated, including excess oil returned to the storage tank.

SUCTION LINE SIZING. The Suction load is determined by:

1. The vertical lift from the oil level in the tank to the pump.2. Pressure drop through valves, f ttings, strainers, etc.3. The friction loss due to oil f ow. This loss varies with: a. Quantity of oil pumped (gph).

b. Length of suction line (feet).c. Diameter of the suction line.d. Number of f ttings.

Although the gear type pumps used on the H series burners are capable of developing higher suction, it is not desirable to operate above 15 inches of mercury vacuum. If the vacuum is greater, f ow may be erratic.

Refer to the manufacturers table for line sizing

1. Check suction capacity.

2. Measure total pipe length (horizontal and vertical).

3. Read up from line “total feet of copper tube” to the intersection line of the specific “suction capacity “ in g.p.h.

4. Read left to column “inches of vacuum at fuel unit”. This is vacuum required to draw oil through pipe listed at given length.

5. Add 1” of vacuum for every foot of lift.

6. Total inches of vacuum (frictional tube loss plus lift).

7. If total exceeds 15”, check next larger pipe size.

RETURN LINE SIZING. Generally, the return line should be sized the same as the suction line.

TWO PIPE - MULTIPLE BURNER SYSTEM. Several options exist for a multiple burner installation. In Figure 2-10 a typical installation showing separate suction lines for each burner with a common return line.Figure 2-11 shows multiple burners with oil supplied by a transfer pump. The circulating pump is sized, in this case for the total suction capacity of all burners. Note that a special pressure regulating valve is required if the fuel unit inlet pressure is above 3 psi.Figure 2-12 shows an installation using a day tank. A pump supplies oil to the day tank.Figure 2-13 shows a f ooded loop system. The circulating pump is sized according to the maximum burner f ring rate for all burners plus a 30% service factor. The burner return lines feed into the common supply line.

NOTEINDUSTRIAL COMBUSTION RECOMMENDS THAT ALL OIL FIRING BURNERS BE EQUIPPED WITH AN OIL STRAINER (IF NOT INCLUDED WITH THE BURN-ER) TO PREVENT PARTICLES FROM CLOGGING THE NOZZLE. IT IS ESSENTIAL TO FOLLOW THE STRAINER MANUFACTURER’S MAINTENANCE SCHEDULE TO ENSURE PROPER FIL TRATION.

10

FIGURE 2-4

FIGURE 2-5

Typical U.L. Gas Train - Low-High-Off System - Size 1 K13 to K25

571-0013

INPUTFROM SUPPLY

PILOTREGULATOR

TOBURNER

PILOTVALVE

PILOTSHUTOFFCOCK

SHUTOFFCOCK

MAINGASVALVE

MAINGASVALVE

REGULATOR

SHUTOFFCOCK

OUTPUTTO BURNER

A

A

Typical U.L. Gas Train - Full Modulation System - Size 1 K13 to K25

571-0014

BUTTERFLYVALVE

SHUTOFFCOCK

MAINGASVALVE

MAINGASVALVE

OUTPUTTO BURNER

INPUTFROM SUPPLY

SHUTOFFCOCK

PILOTREGULATOR

TOBURNER

PILOTVALVE

PILOTSHUTOFFCOCK

A

REGULATOR

A

11

Typical U.L. Gas Train - Low-High-Off, Low-High-Low, Size 2 K30 to K42Full Modulation System - Size 2-3-4 K30 to K145

FIGURE 2-6

571-0015

HIGH GASPRESSURESWITCH

LOW GASPRESSURESWITCH

A

A

A

BUTTERFLYVALVE

SHUTOFFCOCK

MAINGASVALVE

MAINGASVALVE

OUTPUTTO BURNER

INPUTFROM SUPPLY

SHUTOFFCOCK

PILOTREGULATOR

TOBURNER

PILOTVALVE

PILOTSHUTOFFCOCK

A

REGULATOR

Low-High-Off, Low-High-Low Oil System, Size 2 - K30 to K42 FIGURE 2-7

571-0004

MODUTROLMOTOR

NOZZLEPRESSURETAP

N.C.OIL VALVES

FUEL UNIT

OILSUPPLY

OILNOZZLE

FAN HOUSINGBACK CAP

OILRETURN

FUEL UNITPRESSURETAP

12

Full Modulation Oil System Size 1 - K13 to K25 Simplex Nozzle

Full Modulation Oil System Size 2, 3, 4 - K30 to K145 Return Flow Nozzle

FIGURE 2-8

571-0005

METERINGVALVE

MODUTROLMOTOR

NOZZLEPRESSURETAP

N.C.OIL VALVES

OILSUPPLY

FUEL UNIT

OILNOZZLE

FAN HOUSINGBACK CAP

OILRETURN


571-0006

CHECK VALVE

METERINGVALVE

MODUTROLMOTOR

NOZZLEPRESSURETAP

N.C.OIL VALVES

OILSUPPLY

FUEL UNIT

OILNOZZLE

FAN HOUSINGBACK CAP

OILRETURN


FIGURE 2-9

13

Multiple Burners with separate suction lines

Typical Oil Loop for Multiple Burners with Transfer Pump

Typical Installation Using Day Tank

FIGURE 2-10

FIGURE 2-11

FIGURE 2-12

571-0016

OILMETERINGVALVEFUEL

UNIT


UNIT FILTER

GATEVALVE

GATEVALVE

GATEVALVE

CHECKVALVE

CHECKVALVE

CHECKVALVE

BURNERNOZZLE

CHECKVALVE

FILTER

OIL RETURN

OIL INLET

BURNERNOZZLE

OIL INLET

OIL RETURN

GATEVALVE

SUPPLY TO BURNERS

RETURN TO TANK

OILSUPPLY

TANK

571-0017

CHECKVALVE

VOLUMECONTROLBY-PASS

CHECKVALVE

GATEVALVE

PRESSUREGAUGESW/ISOLATORS

PRESSURE GAUGEW/ISOLATOR

BACK PRESSURE VALVESET BELOW 3 PSI

RELIEFVALVE

TRANSFERPUMP

VACUUM OR COMPOUNDGAUGE W/ISOLATOR

CHECKVALVE

GATEVALVE

GATEVALVE

STRAINER

OILMETERING

VALVEFUELUNIT


UNIT FILTER

GATEVALVE

CHECKVALVE

BURNERNOZZLE

CHECKVALVE

FILTER

OIL RETURN

OIL INLET

BURNERNOZZLE

OIL INLET

OIL RETURN

GATEVALVE

SUPPLY TO BURNERS

RETURN TO TANK

OILSUPPLY

TANK

571-0018

GATEVALVE

CHECKVALVE

STRAINER

DAYTANK

RELIEFVALVE

TRANSFERPUMP

VACUUM OR COMPOUNDGAUGE W/ISOLATOR

CHECKVALVE

GATEVALVE

GATEVALVE

STRAINER

OIL

METERING

VALVEFUELUNIT

OIL RETURN

OIL INLET

BURNERNOZZLE

OILSUPPLY

TANK

14

G. INSTALLATION CHECKLIST1. 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:a. Electrical terminals in the control panel and on all elec-trical components.b. Pipe f ttings and unions.c. Tubing connections.d. Nuts, bolts, screws.

2. Open all necessary oil shutoff valves. Do not run pumps or fuel unit without oil.

3. Before connecting electrical current to any component, be sure the voltage is the same as that specif ed on com-ponent nameplates.

4. Before burner operation, be sure all motors are rotating in the proper direction.

5. Before f ring, make sure the burner f ring head and dry areas of the boiler are protected with refractory . The burner mounting f ange must be properly sealed against the vessel front plate.

6. Make certain that the operator in charge is properly instructed in operation and maintenance procedures.

Typical Flooded Loop System

CAUTIONBEFORE OPENING THE MANUAL GAS SHUT-OFF VALVES, READ THE REGULA-TOR INSTRUCTIONS CAREFULL Y. THE INSTRUCTIONS ARE IN THE REGULATOR BOX. FOLLOW THE MANUFACTURER REC-OMMENDATIONS. OPEN SHUT -OFF VALVE ON THE INLET SIDE OF THE REGULATOR SLOWLY AND CAREFULLY TO ALLOW IN-LET PRESSURE TO BUILDUP SLOWLY IN THE REGULATOR UNTIL IT IS FULLY PRES-SURIZED. OPENING THE SHUT-OFF VALVE QUICKLY WILL DAMAGE THE REGULATOR.D O N O T E X C E E D T H E R E G U -L A T O R P R E S S U R E R A T I N G S .

FIGURE 2-13

571-0019 DUPLEX PUMP SYSTEM

6"MINIMUM

VACUUM BREAKER

STRAINERGATEVALVE

VACUUM GAUGEW/ISOLATOR

GATEVALVE

TRANSFERPUMP

GATEVALVE

TRANSFERPUMP

STRAINER

GATEVALVE

VACUUM GAUGEW/ISOLATOR

CHECKVALVE

OILSUPPLY

TANK

PRESSUREGAUGE

GATEVALVE

CHECKVALVE

STRAINER


UNIT

OIL RETURN

OIL INLET

BURNERNOZZLE

PRESSUREGAUGE

GATEVALVE

CHECKVALVE

STRAINER

OILMETERING

VALVEFUELUNIT

OIL RETURN

OIL INLET

BURNERNOZZLE

15

SECTION 3STARTING UP AND OPERATION

A. PREPARATION FOR INITIAL START-UP When the installation is complete and all electrical, fuel, water and vent stack connections are made, make certain said connections are tight. The operator should become familiar with the burner , boiler controls and components. To identify controls and components refer to drawings and contents of Section 1. Adjustment procedures given in Sec-tion 4 should be reviewed prior to f ring. The wiring diagram should also be studied along with the operating sequence of burner programmer. Check the electrical power supply for accordance with the nameplate speci f cations for all motors and controls.

Read and understand starting instructions before at-tempting to operate the burner. The following checks must be made:

BOILER. Check boiler water level. Be sure all boiler valves are installed correctly and positioned properly. Set the high limit control slightly above the operating control. Set operating control at the desired temperature or pressure.

BURNER. For protection in shipment, the f ame safeguard control chassis is shipped unmounted. Check all screw connec-tions before attaching f ame safeguard chassis to base. Screw must be secure to assure low resistance connec-tions. The relay chassis is mounted on the subbase with a screw which, when tightened, completes the connection between the subbase and chassis contacts. Press manual reset button to be sure safety switch contacts are closed.

Check fuses in main panel and in burner control cabinet. Check wiring to the burner control cabinet for compliance with the wiring diagram and local codes. The control cabinet components are 120 volt. If a control transformer is sup-plied, ensure that the supply voltage matches its primary voltage.

Check motor rotation by momentarily closing the starter or relay. Blower rotation is clockwise when viewed from the drive end.

Check the pilot electrode setting. Refer to the ADJUST-MENT section.

Check control linkage for proper movement of the air volume damper and fuel metering components. This can be done by loosening the linkage at the actuator lever and manipulating by hand.

Check the air shutter and adjust low f re setting. Refer to the ADJUSTMENT section.

B. FIRING PREPARATIONS Check to make certain that all plugs, connections, link-ages etc., are tight. Prior to initial f ring, oil f ow and pres-sure should be verif ed.

GAS BURNERS A representative of the gas utility should turn on the gas. Determine by a test gauge upstream of the burner regulator that suff cient pressure exists at the entrance to the gas train. The gas pressure regulator must be adjusted to the pressure required and the pressure setting recorded. On combination fuel models, set the selector switch to gas. On initial start-up it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through pre-purge and pilot sequences to determine that the main gas valve opens. Turn the burner switch “OFF” and let programmer f nish its cycle. Check to see that gas valve closes tightly.

On burners equipped with high and low gas pressure switches, set switch pressure actuating levels and record settings for future service reference.

See the burner specif cation nameplate inside the con-trol panel door for minimum and maximum input rate and required manifold pressure.

When the conditions covered above and in Section 2 are assured, the burner is ready for f ring. Refer to Letter E for starting and operating information.

OIL BURNERS Prior to initial f ring, oil f ow and pressure should be veri-f ed. If the burner is a dual fuel model, make certain that the main gas shut off cock is closed and the fuel selector switch set to “OIL”.

OIL FLOW. If the oil supply tank is below level of oil fuel unit, it is recommended that the suction line be primed with oil prior to starting the pump to avoid possibility of damage to pump through operation without lubrication. To check for proper pump rotation, momentarily energize the starter. With rotation verif ed, operate the pump to de-termine that oil circulation exists. Observe the oil burner pressure gauge. If no pressure shows after a few moments, stop the oil pump and re-prime. If the supply tank is lower than the pump, it is possible that the initial priming of the suction line, followed by operation of the pump, will not establish oil f ow. This might be caused by obstruction in the suction line, excessive lift, inadequate priming, suction line leaks, etc. Until oil f ow is established, avoid prolonged operation of the pump. If oil f ow is not established after a second priming, investigation is required.

16

A vacuum (or compound pressure-vacuum) gauge should be installed at the suction port of the pump. It is advisable that the reading be less than 15” Hg vacuum. Vacuum in excess of this may cause unstable f ring.

OIL PRESSURE AND VACUUM. If vacuum gauge reads higher than calculated, look for restriction in the suction line, a closed valve, kinked copper tubing, plugged f lter, sticking check valve, frozen oil line, undersized oil line, or excessive lift. When there is a positive head of oil at the fuel unit, either from a gravity or by pump circulation, the pressure must not exceed 3 psi at the fuel unit suction inlet. Special pressure regulating valves are available for suction pressure above 3 psi. The fuel unit discharge pressure should be set at 300 psi.

BURNER SETTINGS To ensure reliable and safe burner performance, the location and gap setting of the electrode for direct-spark igniters, and the relative positions of the burner nozzle, diffuser, and air baff e components must be correctly set.The air damper blades must be adjusted, relative to the established f ow rates, to provide the correct amount of air for complete eff cient combustion. These items are preset at the factory , but must be checked prior to placing the burner into initial service, or after conducting any service work that may have altered their position.

Refer to Section 4, ADJUSTMENTS, for the instruc-tions.

COMBUSTION SETTINGS Fuel and air f ow rates are individually adjusted at low f re and at high f re to achieve rated heat input, f ring rate turndown, optimum ef f ciency, safe operation, and the ability to cope with environmental changes (including air temperature, humidity, barometric pressure), and fuel property changes. Refer to the nameplate inside the control panel for minimum and maximum fuel input ratings.

Refer to Section 4, ADJUSTMENTS, for the instruc-tions.

TEST EQUIPMENT The following test equipment should be on site:1. Combustion analyzer with O2 or CO2 indication.2. U-Tube manometer, or pressure gauge, to measure gas pressures (Main and Pilot), pressure and vacuum gauge for the oil burners.3. Inclined manometer to measure draft pressures.4. Smoke spot tester for oil burners and CO analyzer for gas f red units.5. Voltmeter / Ammeter6. Stack Thermometer and Thermocouples.

WARNINGREAD THE FLAME SAFEGUARD MANUAL AND FULLY UNDERSTAND ITS CONTENT BEFORE ATTEMPT-ING T O OPERATE THIS EQUIP-MENT.. SERIOUS PERSONAL IN-JURY OR DEA TH MAY RESULT.

WARNINGSHOULD A ST ARTING F AILURE OCCUR FOR ANY REASON, COM-BUSTIBLE FUMES MA Y FILL THE COMBUSTION CHAMBER. NEV -ER ATTEMPT T O RE-LIGHT THE BURNER UNDER THESE CONDI-TIONS WITHOUT FIRST PURGING

C. SEQUENCE OF OPERATION The programming control sequences the operation of all controls and components through the starting, ignition, f ring, and shutdown cycle. The burner and control system are in starting condition when: a. The operating and high limit control (temperature or pressure) are below their cutoff setting; b. All power supply switches are closed; c. Power is present at the control panel. Refer to the manufacturer ’s literature on programming controls and burner wiring diagrams for detailed informa-tion.

D. ELECTRICAL INTERFERENCE TEST Prior to putting the burner into service, conduct the fol-lowing test to ascertain that ignition spark will not cause the f ame relay to pull in.

GAS FIRED Close the pilot and main line manual gas valves. Start the burner and at time of pilot trial with just the electrical ignition system energized. The f ame relay should not pull in (i.e. should not be energized). Upon completion of successful test, proceed with start-up procedures.

OIL FIRED Disconnect the electrical power to the burner . Discon-nect the electric oil safety shutoff valve. Reconnect electric power. Close the pilot line manual gas valve, if used. Start burner and at the time of pilot trial, with just the electrical ignition system energized. The f ame relay should not pull in. Upon completion of successful test, disconnect power supply. Reconnect oil safety shutof f valve and turn on manual pilot gas valve. Reconnect power supply and proceed with start-up procedures.

17

E. START-UP AND OPERATING

GAS BURNERS:

Performing A Gas Valve Leak Test (Bubble Test) A gas valve leak-test must also be performed on the automatic safety shutof f valves located in the main gas train prior to any initial commissioning or subsequent maintenance of the burner and gas train systems – where automatic valve proving systems interlocked with the main burner safety control are not provided. This test should be performed periodically to ensure no leakage of valves in their closed or de-energized position.

Refer to the diagram below when following this procedure. The unit should be taken out of service if the unit fails any of the following tests. Any defective part must be replaced prior to putting the equipment back into service.

• Close (or shut off) manual valve [7] downstream of the automatic safety shutoff valves, trapping gas pressure between the safety shutoff valves and manual valve and causing a f ame failure. This should close the auxiliary safety shutoff valve [4] and main gas safety shutoff valve [5]. If both or either valve fails to close, do not proceed further until you correct the problem.

• Release gas pressure at the leak test cock [8B] between manual valve [7] and main gas safety shutoff valve [5], then conduct a bubble test for leak through blocking valve [5]. If no leak, close the test cock.

• Release gas pressure at test cock [8A] and bubble test for leak through auxiliary safety shutoff valve [4]. If you do not observe a leak, close test cock and go to next step. If either valve leaks, correct the problem and retest 10 times before proceeding.

• When there are no valve leaks, open manual valve [7] and relight the burners. Then close manual valve [1]. The safety shutoff and blocking valve should close due to low gas pressure.

• Relight the burners. Reduce the high gas pressure switch [6] setpoint setting until it reaches the operating gas pressure, which should cause the auxiliary and main gas safety shutoff valves to close from high gas pressure. Return the setpoint to its original position before proceeding.

• Shut off the combustion air blower. This should cause a failure due to low air pressure and cause the safety valves to close.

• Reset all manual valves to their normal setting for operation. Make sure all electric valves are operating normally. Make sure all test cocks are closed before resuming normal operation.

WARNINGFAILURE TO FOLLOW THIS PROCEDURE MA Y RESULT IN EXPLOSION, FIRE, PROPER TY DAMAGE AND PERSONAL INJUR Y. THIS PRO-CEDURE MUST BE PERFORMED ONL Y BY AUTHORIZED AND QUALIFED PERSONNEL.

18

Close the downstream main and pilot gas cocks. Make sure the “ON-OFF” switch is in the “OFF” position. Actuate the manual reset button of the f ame safeguard control to close the safety switch contacts. For LOW-HIGH-OFF or LOW -HIGH-LOW and FULL MODULATION models set the “MANUAL-AUT O” switch to the “MANUAL” position. Set the manual potentiometer to low f re position.

Open the gas pilot cock. check pressure. Normal setting is 3” to 6” WC when the pilot is burning.

Set the “ON-OFF” switch to “ON”. The burner will start and pre-purge. After pre-purge, the ignition transformer and the gas pilot solenoid are energized.

On initial start-up it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through prepurge and pilot sequence. Then determine that main gas valve opens. When this is con f rmed, turn the burner switch “OFF” and let programmer f nish its cycle. Check to see that gas valve has closed tightly.If ignition does not occur, turn the burner switch “OFF” and allow programmer to recycle for a new ignition trial.

Turn burner “ON” and after pilot ignition when the f ame relay pulls in, the slow opening, motorized, main gas valve is energized. Slowly open the downstream manual shutoff gas cock. Main f ame should ignite at this time. The gas valve and air damper continue advancing until high f re is reached.

Do not repeat unsuccessful light of f attempts without rechecking burner and pilot adjustment. Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt. Set the gas low f re rate by adjusting butterf y valve and air linkage. Refer to the adjustment section of this manual. Using combustion analysis instrument adjust the low-f re. Typical combustion analysis for low-f re is 4 to 5% O2 on standard turndown systems. Verify the minimum input rate by measuring the gas meter.

When low f re is adjusted, shut down burner. Restart sever-al times to be sure the low f re setting is suitable. Readjust if necessary. Never start the burner with fuel vapor in the furnace. In case of emergency, open main power switches and close all fuel valves. After combustion adjustments are satisfactorily set, allow the heating vessel to slowly reach normal operating pressure or temperature.

After the boiler has reached operating temperature or pres-sure, turn the potentiometer switch in small increments to the high f re position. Check high f re at this point using combustion instruments. High f re combustion analysis typically is 2 to 3.5 percent O2. Verify maximum input rate by measuring the gas meter.

Do not disturb established low f re adjustment. Allow the burner to return to low f re position before adjusting high or intermediate settings. CO levels should be less than 400 ppm on an air-free basis at all f ring rates, with <50 ppm as the target value.

When conditions covered above are assured, refer to Sections F and G of this chapter.

OIL BURNERS The fuel selector switch should be set to “OIL” and the “ON-OFF” switch is in the “OFF” position. Actuate the manual reset button of the f ame safeguard control to close the safety switch contacts.

Set the “ON-OFF” switch to “ON”. The burner will start and pre-purge. After pre-purge, the ignition transformer will direct spark. If the f ame detector proves the presence of a satisfactory pilot, the programmer will proceed to main f ame ignition.

Make initial air shutter settings for smooth ignition. Re-turn line oil pressure should be set according to Section 4, ADJUSTMENTS. Do not repeat unsuccessful light of f attempts without rechecking burner and pilot adjustment. Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt. Set the oil low f re rate by adjusting the oil return pressure and air linkage. Refer to the adjustment section of this manual. Using combustion analysis instrument adjust the low f re. Typical combustion analysis for low-f re is 4 to 5% O2.

When low f re is adjusted, shut down burner . Restart several times to be sure the low f re setting is suitable. Readjust if necessary . Never start the burner with fuel vapor in the furnace. In case of emergency , open main power switches and close all fuel valves. After combustion adjustments are satisfactorily set, allow the heating vessel to slowly reach normal operating pressure or temperature.

After the boiler has reached operating temperature or pressure, turn the potentiometer switch in small increments to the high f re position. This will cause the metering valve to close, resulting in an increase in the oil pressure feeding the burner nozzle. In high f re the oil metering valve should be in the fully closed position and the fuel oil pressure should be about 300 psi. Check high f re at this point using combustion instruments. High f re combustion analysis typically is 3 to 4.0% percent O2. Verify maximum input rate by measuring the oil meter if available or by weighing the oil.

The burner should be set-up and maintained to yield smoke spot levels less than a #1 spot (ASTM D2156 Shell-Bacharach Scale) to minimize soot build-up in the boiler.

19

Do not disturb established low f re adjustment. Allow the burner to return to low f re position before adjusting high or intermediate settings.

When conditions covered above are assured, refer to letters F and G of this section.

COMBINATION GAS-OIL BURNERS In general, the combination fueled system is to be started f rst using oil, because, as a fuel, oil has a greater combustion air requirement than natural gas. Refer to the Gas burner or Oil burner adjustment procedures and to Section 4, ADJUSTMENTS.

Once the adjustments are set for oil, shut-down the burner and re-start and adjust the natural gas fuel. DO NOT READJUST THE AIR SHUTTERS. The adjustment is made by balancing the fuel input rate against the existing f ow of combustion air.

When conditions covered above are assured, refer to letters F and G of this section.

F. NORMAL OPERATION Normal operation must be with the “MANUAL-AUT O” switch selector at “AUTO”.

In automatic operation, the operating cycle always pro-ceeds sequentially through pre-purge, pilot ignition, main f ame ignition, run and post-purge. The length of purge and ignition trial vary according to the type of programmer used. During the run cycle, burner input is regulated to the load demand by the modulating pressure or temperature control on the boiler. The burner will continue to modulate until the operating pressure or temperature is reached.

Programmer control operation should be tested when the burner is initially placed into service, when a control is replaced, and at scheduled intervals in the maintenance program.

Refer to adjustments procedures and maintenance in-structions given in Sections 4 and 5.

G. SHUTDOWN When the operating limit control setting is reached or the burner switch is turned “OFF”, the following sequence occurs:

The fuel valve(s) de-energize and f ame extinguishes. The blower motor continues running during post-purge (if so equipped with post-purge feature).

At the end of the post-purge the blower motor is de-energized. The programmer returns to its starting position and stops. Unit is ready to restart.

Abnormal shutdown might result from motor overload, f ame outage, low water, current or fuel supply interruption, combustion or atomizing air pressure below minimum level, tripped circuit breakers, blown fuses, or other interlock devices. Check for cause and correct before restarting burner.

Safety shutdown caused by ignition or f ame failure will actuate a red indicator light and energize an audible alarm (if so equipped). If the programmer has a non-recycling interlock circuit, any interruption in this circuit during the pre-purge or f ring cycle will cause a safety shutdown. This type of shutdown requires manual reset of the program-ming control and must be corrected before operation can be resumed.

SIZE 1 & 2 COMBINA TION GAS/OIL UNITS USE A DIRECT COUPLING FROM THE BLOWER MOTOR TO THE OIL PUMP. WHEN FIRING GAS FOR AN EXTENDED PERIOD OF TIME, THE COUPLING SHOULD BE MANUALLY REMOVED AND REPLACED ONLY WHEN FIRING OIL. IF THE COUPLING IS LEFT CONNECTED TO THE BLOWER MOTOR, ENSURE THAT THERE IS PROPER OIL CIRCULATION AT ALL TIMES TO AVOID DAMAGE AND SEIZURE OF THE PUMP.

NOTE

Figure 3-1571-0020

FLEXIBLECOUPLING

ACCESSCOVER

BLOWERMOTOR

IMPELLERIMPELLER

ACCESSCOVER

BLOWERMOTOR

20

SECTION 4ADJUSTMENTS

A. GENERAL While each burner is tested at the factory for correct operation before shipment, variable conditions such as burning characteristics of the fuel used and operating load conditions may require further adjustment after installation to assure maximum operating eff ciency. Prior to placing the boiler into initial service, a complete inspection should be made of all controls, connecting piping, wiring, and all fastenings such as nuts, bolts and setscrews to be sure that no damage or misadjustments occurred during shipment and installation. A combustion eff ciency analysis made during the initial start-up will help to determine what additional adjustments are required in a particular installation.

B. COMBUSTION ADJUSTMENT ON OIL AND GAS Ef f cient combustion cannot be properly judged by f ame appearance, although it may help in making preliminary settings. The proper settings of air-fuel ratios must be determined by f ue gas analysis. Combustion gas analysis indicates the air to fuel ratio and the degree of complete combus-tion. Instruments are available to measure carbon dioxide (CO2), oxygen (02), and carbon monoxide (CO). At no time should CO2 measurements alone be used to indi-cate proper excess air levels. Only O2 measurement can def nitively show whether suff cient air has been provided for combustion.

STACK TEMPERATURE Net stack temperature is obtained by subtracting the ambient temperature from the f ue gas temperature. A high net stack temperature indicates wasted heat. Decreasing either the temperature or the volume of the f ue gas, or both can reduce stack heat loss. Flue gas temperature is reduced by improving heat transfer or by reducing excess combustion air. A certain amount of excess air is necessary to complete combustion. More ef f cient burners require minimum excess air.

SMOKE MEASUREMENT Smoke measurements can be made using a variety of different methods. The standards will vary somewhat according to the equipment used, and instructions accom-panying the instrument should be followed. Smoky combustion can result from: Improper air delivery, insuff cient draft, improper fuel viscosity, improper fuel-air ratio, excessive air leaks in the combustion chamber , or improper fuel oil temperature.

TEST EQUIPMENT The following test equipment should be used to set-up and adjust the burner correctly:

1. Combustion analyzer for O2 or CO2 indicator. 2. U-Tube manometer, or pressure gauge, to measure gas pressures (Main and Pilot), Vacuum and pressure gauges for oil. 3. Inclined manometer to measure draft pressures. 4. Smoke spot tester for oil burners and CO analyzer for gas f red units. 5. Voltmeter / Ammeter 6. Stack Thermometer and Thermocouples.

AIR FLOW ADJUSTMENTS The K/Series burners have a unique air shutter design that enables precise, independent air f ow rate adjustments for both the high-f re and low-f re operating points. This design incorporates a variable main air shutter (mounted on a shaft and direct-coupled to the modulating motor), plus two adjustable, but non-modulating, air shutters.

The modulating main air shutter regulates the f ow of inlet air through the fan at f ow rates between high- f re and low-f re conditions according to the modulating motor position. One non-modulating air shutter , for high- f re combustion air control, is adjusted to provide the correct amount of air while the system is operating at high-f re fuel input rate with the main air shutter fully open. The other non-modulating shutter, for low-f re combustion air control, is adjusted to provide the correct amount of air with the system operating at low-f re input rate with the main shutter completely closed.

The three air shutters are mounted inside the air box assembly. The high-f re and low-f re shutters are mounted on independent shafts. A pointer, mounted on each shaft, indicates the set position of each non-modulating shutter. Adjustment of these shutters is accomplished by loosening a setscrew that holds the shutter shaft within a stationary collar mounted on the air box.

COMBUSTION SETTINGS Fuel and air f ow rates are individually adjusted at low-f re and at high- f re to achieve rated input, f ring rate turndown, optimum ef f ciency, safe operation, and the ability to cope with environmental changes (including air temperature, humidity , barometric pressure), and fuel

THE LOW -HIGH-OFF, LOW -HIGH-LOW BURNERS ARE EQUIPPED WITH A SINGLE AIR DAMPER BLADE. THE SPECIAL AIR SHUTTER DESIGN IS APPLICABLE ONLY FOR THE FULL MODULATION SYSTEMS.

NOTE

21

property changes. Turndown capability for oil is less than that for gas due to the excess air requirement of oil for clean combustion. Therefore, on combination fueled burners, gas turndown performance may be restricted (or determined) by the excess air levels set initially for oil combustion. Two key components residing in f ue gas are used to optimize combustion eff ciency; excess air and unburned fuel. The system should be adjusted to the minimum excess air quantity that provides low levels of unburned fuel with suff cient remaining oxygen to cope with normal atmospheric and fuel related changes. Unburned fuel is measured as carbon monoxide (CO) when burning natural gas, and smoke spots when burning oil.

GAS ADJUSTMENTS Low- f re combustion analysis typically is 7 to 9 percent CO2 and less than .04 percent CO (400 ppm). High- f re reading typically is 9 to 10.5 percent O2 and less than .04 percent CO. The K/Series burners are capable of operat-ing at low excess air and less than 50 ppm CO levels at all f ring rates.

FUEL OIL ADJUSTMENTS Adjust for a “clean f re”. Typically for No. 2 oil, CO2 is 8 to 11 percent at low-f re and 10 to 13 percent at high-f re. The burner should be set-up and maintained to yield smoke spot levels less than a #1 spot (ASTM D2156 Shell-Bacharach Scale) to minimize soot build-up in the boiler.

C. GAS PILOT FLAME ADJUSTMENT Burner models KG-KLG and KL-54 to 145 are equipped with a gas pilot system. The gas pilot f ame is regulated by adjusting the pressure setting of the pilot regulator. Normal setting is 3 to 6” WC when the pilot is burning. The f ame must be suff cient to be proven by the f ame detector and ignite the main f ame. Although it is possible to visibly ad-just the size of the pilot f ame, obtain a proper DC volt or microamp reading of the f ame signal. The f ame safeguard amplif er has a meter jack for this purpose. At initial start-up and during planned maintenance, test the pilot f ame signal, pilot turndown, and safety switch lockout. Refer to the f ame safeguard instruction manual.

Check the pilot electrode setting. The pilot is accessible by loosening the four screws on the side of the blast tube and disconnecting the gas line.

D. DIRECT SPARK OIL PILOT ADJUSTMENT Burner models KL-13 to 42 are equipped with a direct spark ignition. Remove the oil drawer assembly and check electrode settings and nozzle size.

E. BURNER SETTINGS To ensure reliable and safe burner performance, the location and gap setting of the electrodes, and the rela-tive positions of the burner nozzle, dif fuser and air baf f e components must be set correctly. These items are preset at the factory , but must be checked prior to placing the burner into initial service, or after conducting any service work that may have altered their position. The nozzle/dif fuser assembly must be removed from inside the burner to enable measurement and adjustment. Remove as follow:1. Lock out and tag the electrical power supply to theburner to prevent inadvertent operation during check-out or maintenance activities.2. Disconnect the high voltage power supply from the oil-spark-ignition electrodes (if installed).3. Disconnect the f ame scanner and oil piping from the end of the blast tube.4. Remove the fasteners that secure the drawer to the side of the fan housing, and remove the completeassembly.5. For burners with a gas pilot: Disconnect the pilot lineand loosen the locking screws on the pilot accesscover located on the side of the blast tube. Disconnect the high voltage ignition cable by pulling it straight back, away from the pilot assembly. The pilot assembly will slide back

Size 1 & 2 Gas Pilot

Figure 4-1Size 3 & 4 Gas Pilot

AN UL TRA-VIOLET FLAME SENSOR ELECTRI-CAL SP ARK INTERFERENCE TEST MUST BE PERFORMED AFTER FINAL ADJUSTMENT. SEE SECTION 3 OF THIS MANUAL FOR ADDITIONAL INFORMATION.

WARNING

571-0025

CENTERELECTRODE

IN OPENING

ELECTRODEFLUSH W/END

OF TUBE

8-3/4"

571-0026

TIP TO TUBEGAP OF 1/32"

ELECTRODE ENDWITHIN 1/4"

FROM TUBE END

9-5/16"

SET ELECTRODETIP AT THE

9:00 O'CLOCKPOSITION

22

Direct spark ignition

and away from the diffuser. Turn the assembly and retract it through the access hole. Check the electrode position as illustrated in Figure 4-1. Reassemble in reverse order.

Measure the position and gap of the pilot electrodes and compare to the dimensions in Figure 4-2. Adjust as follows:

1. Loosen the locking screws on the spark ignition clamp assembly.2. Rotate and slide each electrode in the clamp, as neces-sary, to achieve the correct position relative to the burner tip. 3. Tighten the locking screws securely to lock the electrode in position. Apply a lock-tight type compound to the screws before tightening. Measure the position of the tip of the nozzle to the diffuser and compare to the following drawer assembly drawings.Adjust as follows:1.Loosen the locking screws on the diffuser clamp. 2.Slide the dif fuser clamp along the length of the burner pipe until the correct dimension is achieved.3. Tighten the diffuser clamp securely to the burner pipe. Apply a lock-tight type compound to the screws before tightening.4. Carefully install the drawer assembly into the burner . Reconnect the oil line, scanner , and high voltage power cable to the assembly.

Measure the position of the dif fuser to air baf f e and compare to the following drawer assembly drawings. Adjust as follows:1. Measure the distance between the leading edge of the diffuser and the front face of the inner ring on the air baff e assembly.2. If adjustment is required, loosen the burner pipe locking setscrew located on the rear cap at the top of the fan housing, and slide the burner pipe until the correct dimension is achieved.3. Tighten the burner pipe locking setscrew securely.

Size 1, KL & KLG-13 to 25Figure 4-3

Figure 4-2

571-0027

7/16" FROMCENTER OF NOZZLETIPS TO BOTTOMEDGE OF THEELECTRODES

1/8" BETWEENINNER EDGES OFTHE ELECTRODES

1/4" FROMNOZZLE TIPS TO

OUTER EDGE OFTHE ELECTRODES


Size 3, KL & KLG-54 to 84 Figure 4-5


NOTEMaximum valve inlet pressure for the V4944 is 0.5 PSI. If line pressure is greater, an over pressure device is to be installed down stream of main gas regulator. (CSD-1-CF160)

23

F. PILOT TURN DOWN TESTFor burners equipped with a gas pilot, conduct the follow-ing test:1. Turn the burner switch on. This will start the blower motor and initiate the prepurge sequence. Make sure a pressure gauge 0-10” w.c. or manometer is installed in the pilot line to monitor the pilot gas pressure.2. When the pilot comes on, put the programmer timer on pilot hold by placing the Run-Test switch of the f ame safeguard to the “Test” position.

Refer to the fl ame safeguard control manual instruc-tions.

3. Check the f ame signal strength. Adjust the f ame signal by increasing or decreasing pilot gas pressure with the regulator spring. Normal setting is 3” w.c. to 4” w.c.4. Perform a pilot turndown test by reducing the pilot pres-sure very slowly until the scanner looses sight of the f ame and give a f ame lock-out, than reset the adjust ment to normal level. Note the minimum pressure level.5. After adjusting the pressure back to normal level, set the programmer to the “Run” position. Main f ame will come on and the burner is in the low f re position.6. Start and stop the burner several times to ensure proper pilot setting.

G. LOW-HIGH-OFF & LOW-HIGH-LOW

BURNER ADJUSTMENTS Refer to the burner data plate located inside the control panel door. The nameplate will list the burner information: Burner and control voltage, phase, cycle, motor amperage, maximum and minimum fuel input settings, manifold pres-sure (at zero furnace pressure. Add the furnace pressure to get the correct manifold pressure at maximum f ring rate). These procedures assume that the pre-start-up tasks, check list, electrical interference test, and pilot turn-down tests, have been performed in accordance with the instruc-tions in this manual. Allow boiler to fully warm up before making adjustments for most eff cient combustion. Refer to the boiler instruction manual for the boiler controls settings.

GAS BURNERS The gas burner adjustments on a Low-High-Off system consist of the gas pressure regulator, butterf y gas valve, low and high gas pressure switches, and air damper. The auxiliary switch inside the M436 Mod motor makes or breaks the high- f re gas. See Fig.10 for switch adjustment. The Low-High-Low boiler control energizes the M436 motor , driving it to high- f re. When the boiler control denergize the M436, a built in return spring drives it to the low-f re position.

The Size 1, KG-13 to 25, use a Honeywell V4944 two-stage solenoid operated diaphragm valve. No butter f y

valve is used. This valve uses two pressure regulators (low-f re and high- f re) and two solenoids to provide two distinct stages of pressure regulation. High-f re is obtained when the 2nd style solenoid is energized by the auxiliary switch in the M346 Mod Motor.1. Open the manual gas shut-off cocks.2. Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator. Make sure they are in accordance with the regulator specif cations. The gas pressure required at the manifold is the pressure that is required to f re the burner at its rated capacity. To adjust the regulator, unscrew the cap located on top and turn the adjustment screw clockwise to increase pressure, or counter-clockwise to decrease pressure.3. Turn the burner switch to the ON position.4. Set the thermostat or control to energize the V4944 valve and check f nal outlet pressure. Allow enough time for the pressure to stabalize (valve outlet pressure measurements are made at a point approximately f ve pipe diameter downstream from the valve outlet). Low- f re outlet range is 0.85” wc to 2.0” wc for natural gas and high- f re outlet range is 3” wc to 4.5” wc.5. To adjust the pressure, temporarily remove the slotted aluminum screw cap and gasket from the housing that contains the regulator adjustment setscrew. Turn the ad-justment setscrew clockwise to increase the pressure or counterclockwise to decrease the pressure setting. Allow enough time for the pressure to reach equilibrium between pressure adjustment.6. After a few seconds, the O 2 analyzer should have an accurate reading of the O2 present in the f ue gas. Normally, O2 levels are set between 4 to 6 percent at low- f re, with less than 50 ppm CO. To obtain the proper readings, adjust the air shutter and low-f re regulator pressure.7. Operate the boiler at low-f re until it is up to operating pressure (steam) or temperature (hot water). 8. Bring the burner to the high-f re position and adjust the regulator pressure. Adjust the high-f re gas input to match maximum rating. Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate. Verify and record your readings and pressures. High- f re is typically 2 to 4% O2 with less than 50 ppm CO.

The burner should be adjusted to provide correct fuel f ow at a constant rate, at the low f re and high f re position as indicated on the burner data plate. This is achieved by clocking the gas f ow at the gas meter. The gas utility or gas meter calibration data, should be consulted to determine the correction factors to be applied to the meter.

Use the following formula to determine actual f ow:

Where:HHV = The higher heating value of the gas in Btu/ft3 (contact your local gas company for an exact measure-ment).

Gas Input = HHV x x x x 29.92

520T + 460

P + P 3600 s hr

RATE ft s

3atm gas

gas

BTU hr

24

Patm = Atmospheric pressure in inches of mercury.

Pgas = Gas pressure ahead of the volumetric f ow meter in inches of mercury.

Tgas = Gas temperature at the volumetric f ow meter in Deg.F

RATE = Natural gas rate taken with the volumetric f ow meter in ft3 /second

9. After completing all adjustments, replace the regulators gaskets and slotted aluminum screw caps. Tighten all link-ages and marked settings. Complete the Start-Up report at the end of this section.

The size 2, KG-30 to 42, use a butterf y gas valve to control the gas f ow to the burner. The M436 Mod motor controls the position of the valve.1. Open the manual gas shut-off cocks.2. Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator . Make sure they are in accordance with the regulator speci f cations. The gas pressure required at the manifold is the pressure that is required to f re the burner at its rated capacity. To adjust the regulator, unscrew the cap located on top and turn the adjustment screw clockwise to increase pressure, or counterclockwise to decrease pressure.3. Turn the burner switch to the ON position.4. The burner will start and be in the low-f re position. 5. After a few seconds, the O 2 analyzer should have an accurate reading of the O 2 present in the f ue gas. Nor-mally, O2 levels are set between 4 to 6 percent at low-f re, with less than 50 ppm CO. To obtain the proper readings, adjust the gas butterf y opening and air shutter. Take note of the readings and pressures at the burner manifold and gas train.6. Operate the boiler at low- f re until it is up to operating pressure (steam) or temperature (hot water).7. Bring the burner to high-f re position. Adjust the high-f re gas input to match maximum rating. At high-f re, the but-terf y valve should be near the full open position. Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate. Verify and record your readings and pressures. High-f re is typically 2 to 4% O 2 with less than 50 ppm CO.8. Adjust the low and high gas pressure switches by turn-ing the adjusting screw until indicator moves to a pressure slightly lower than normal operating pressure for the low gas pressure switch, and slightly higher for the high gas pressure switch (usually 20% below and 20% higher than normal pressure).9. Verify low-f re and high- f re rate by clocking the meter as previously explained.

OIL BURNERS The Suntec B2TD-8842 oil pump is typically incorporated and is a two-stage, two step oil pump. The low-f re pres-

sure adjustment is 100-200 PSI (solenoid de-energized). High-f re pressure adjustment is 200-300 PSI (solenoid energized).1. Turn the burner switch to the ON position.2. Adjust low f re with the oil pressure regulating valve to have approximatly 100 to 200 PSI, and adjust the air shutter for a clean f re. Record your combustion reading from the f ue gas analyzer , normally 8 to 1 1 percent O 2 and less than No.2 Smoke (Bacharach). To adjust the oil pressure regulating valve, remove lockscrew and adjust pressure by turning the allen screw clockwise to increase pressure, and counterclockwise to reduce pressure.3. Operate the boiler at low-f re until it is up to operating pressure (steam) or temperature (hot water).4. Adjust the high-f re fuel input to match maximum oil pressure. At high-f re, the pressure should be 300 PSI. Verify and record your readings and pressures. High-f re is typically 11 to 13% CO2 with less than No.2 smoke. The burner should be adjusted to provide correct fuel f ow at a constant rate, at the low-f re and high-f re position as indicated on the burner data plate.5.Tighten all linkages and marked settings. Complete the Start-up report at the end of this section.

COMBINATION GAS-OIL BURNERS In general, the combination fueled system is to be started f rst using oil, because as a fuel, oil has a greater combustion air requirement than natural gas. After being completely adjusted for oil combustion, the burner is re-started and adjusted using natural gas as fuel. Combustion adjustment of the combination burner for natural gas involves balancing the input rate only against the existing f ow of combustion air, as established initially for oil.Do not readjust the air shutter when tuning the combi-nation burner for combustion of natural gas.1. Turn the fuel selector switch to the OIL position.2. Turn the burner switch to the ON position.3. Proceed with start-up and adjustments using the same procedures def ned in the Oil Burners section.4. After the system has been completely adjusted for oil f ring, place the burner switch OFF, and position the fuel selector switch to GAS.5. Proceed with start-up and adjustments using the same procedures def ned in the Gas Burners section. Do not alter the air settings set for oil. Correct your O2 levels by adjusting the butterf y valve for Size 2 models, and the regulators low and high pressures for Size 1 models.

H. FULL MODULATION BURNER ADJUSTMENTS Refer to the burner data plate located inside the control panel door. The nameplate will list the burner information: Burner and control voltage, phase, cycle, motor amperage, maximum and minimum fuel input settings, and manifold pressure (at zero furnace pressure. Add the furnace pres-sure to get the correct manifold pressure at maximum f ring rate.). These procedures assume that the pre-start-up tasks,

25

check list, electrical interference test, and pilot turn-down tests, have been performed in accordance with the instruc-tions in this manual. Allow boiler to fully warm up before making adjustments for most eff cient combustion. Refer to the boiler instruction manual for the boiler controls settings.

GAS BURNERS The gas burners adjustments on a full modulation burner consist of the gas pressure regulator, butterf y gas valve, low and high gas pressure switches, and air dampers.1. Open the manual gas shut-off cocks.2. Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator. Make sure they are in accordance with the regulator specif cations. The gas pressure required at the manifold is the pressure that is required to f re the burner at its rated capacity. To adjust the regulator, unscrew the cap located on top and turn the adjustment screw clockwise to increase pressure, or counter-clockwise to decrease pressure.3. Set the Manual-Auto switch on the “Manual” position.4. Position the manual f ame control potentiometer in the CLOSED (Low-Fire) position.5. Turn the burner switch to the ON position.6. The burner will start and be in the low-f re position.7. After a few seconds, the O2 analyzer should have an ac-curate reading of the O2 present in the f ue gas. Normally, O2 levels are set between 4 and 6 percent at low-f re, with less than 50 ppm CO. To obtain the proper readings, adjust the gas butterf y opening and low-f re air shutter. Take note of the readings and pressures at the burner manifold and gas train.8. Operate the boiler at low-f re until it is up to operating pressure (steam) or temperature (hot water). Then increase the fuel input to the boiler by turning the manual f ame control potentiometer towards OPEN in small increments. This will cause the butterf y valve to open, allowing more gas into the burner.9. At each point, allow the burner to operate for a few minutes before recording your O2, CO and pressure readings. Observe that your O2 and CO levels remain within an acceptable limit. Adjust the pressure regulator, as necessary, to correct this situation. For burners with the cam trim option, adjust the cam screws throughout the range to obtain correct O2 and CO levels. Continue to do this until the burner reaches high f re (the potentio-meter is at the OPEN position).10. Adjust the high-f re gas input to match maximum rating. At high-f re, the butterf y valve should be near the full open position. Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate. Verify and record your readings and pressures. High-f re is typically 2 to 4% O 2 with less than 50 ppm CO as a target value. Adjust the high-f re excess air rate using the high-f re shutter adjustment.11. Modulate the burner to low- f re. Verify the readings once again. The burner should be adjusted to provide correct fuel

f ow at a constant rate, at the low-f re and high-f re position as indicated on the burner data plate. This is achieved by clocking the gas f ow at the gas meter. The gas utility or gas meter calibration data, should be consulted to determine the correction factors to be applied to the meter

Use the following formula to determine actual f ow:

Where:

HHV = The higher heating value of the gas in Btu/ft3 (contact your local gas company for an exact measure-ment).

Patm = Atmospheric pressure in inches of mercury.

Pgas = Gas pressure ahead of the volumetric f ow meter in inches of mercury.

Tgas = Gas temperature at the volumetric f ow meter in Deg.F

RATE = Natural gas rate taken with the volumetric f ow meter in ft3 /second

12.Adjust the low and high gas pressure switches by turning the adjusting screw until indicator moves to a pressure slightly lower than normal operating pressure for the low gas pressure switch, and slightly higher for the high gas pressure switch (usually 20% below and 20% higher than normal pressure). 13.Tighten all linkages and marked settings. Complete the Start-up report at the end of this section.14.Turn the Manual-Auto switch to AUTO. The burner will now modulate according to the load demand to the boiler.

OIL BURNERS The oil burner adjustments consist of the oil metering valve and air shutters. The f ring rate is regulated by a metering valve in the nozzle return line. At low-f re, the arrow on the valve points to approximately number 7, and at high-f re it is in the closed position (no return f ow), approximately at number 2.The oil metering valve position will vary the oil pressure to the nozzle. An oil pressure gauge should be installed in the return line to monitor the oil pressure. Oil pressure at low-f re is approximately 80 to 100 PSI and 300 PSI at high-f re. Size 1, 2 and 3 K burners use a simplex nozzle. Size 4 K burners use a return f ow nozzle.1. Set the Manual-Auto switch on the “Manual” position2. Position the manual f ame control potentiometer in the CLOSED (Low-Fire) position.3. Turn the burner switch to the ON position.4. The burner will start and be in the low-f re position.5. Adjust low-f re with the metering valve position to have approximately 80 to 90 PSI, and adjust the low- f re air shutter for a clean f re. Record your combustion reading

Gas Input = HHV x x x x 29.92

520T + 460

P + P 3600 s hr

RATE ft s

3atm gas

gas

BTU hr

26

from the f ue gas analyzer, normally 8 to 11 percent CO2 and less than No.2 Smoke (Bacharach).6. Operate the boiler at low- f re until it is up to operating pressure (steam) or temperature (hot water). Then increase the fuel input to the boiler by turning the manual f ame control potentiometer towards OPEN in small increments. This will cause the metering valve to close, resulting in an increase in the oil pressure feeding the burner nozzle.7. At each point, allow the burner to operate for a few min-utes before recording your CO2, CO, Smoke and pressure readings. Observe that your CO 2 and CO levels remain within an acceptable limit. Adjust the oil pressure as nec-essary, to correct this situation. For burners with the cam trim option, adjust the cam screws throughout the range to obtain correct CO 2 and CO levels. Continue to do this until the burner reaches high- f re (the potentiometer is at the OPEN position).8. Adjust the high- f re fuel input to match maximum oil pressure. At high-f re, the metering valve should be in the fully closed position and the pressure should be 300 PSI. Verify and record your readings and pressures. High- f re is typically 11 to 13% CO2 with less than No.2 smoke. Ad-just the high-f re excess air rate using the high-f re shutter adjustment. 9. Modulate the burner to low-f re. Verify the readings once again. The burner should be adjusted to provide correct fuel f ow at a constant rate, at the low f re and high f re position as indicated on the burner data plate.10. Tighten all linkages and marked settings. Complete the Start-up report at the end of this section.11. Turn the Manual-Auto switch to AUTO. The burner will now modulate according to the load demand to the boiler.

COMBINATION GAS-OIL BURNERS In general, the combination fueled system is to be started f rst using oil, because as a fuel, oil has a greater combus-tion air requirement than natural gas. After being completely adjusted for oil combustion, the burner is re-started and adjusted using natural gas as fuel. Combustion adjustment of the combination burner for natural gas involves balancing the input rate only against the existing f ow of combustion air, as established initially for oil.Do not readjust the air shutters when tuning the com-bination burner for combustion of natural gas.

1. Set the Manual-Auto switch on the “Manual” position.2. Position the manual f ame control potentiometer in the CLOSED (Low-Fire) position.3. Turn the fuel selector switch to the OIL position.4. Turn the burner switch to the ON position.5. Proceed with start-up and adjustments using the same procedures def ned in the Oil Burners section.6. After the system has been completely adjusted for oil f ring, place the burner switch OFF, and position the fuel selector switch to GAS.7.Proceed with start-up and adjustments using the same procedures def ned in the Gas Burners section. Do not

alter the air settings set for oil. Correct your O2 levels by adjusting the butterf y valve.

571-0023

HIGH FIRE

HIGH FIREAIR SHUTTER(W/INDICATOR)

LOW FIREAIR SHUTTER(W/INDICATOR)

MAIN AIRSHUTTER

(SHOWN IN LOW FIRE POSTION)

FIGURE 4-7

571-0022

TYPICAL LOCATION OFTHE POINTER WHEN ATTYPICAL LOCATION OFTHE POINTER WHEN AT

HIGH FIRE

OPENCLOSED

16

14

12108

64

20

18

FIGURE 4-8

27

FIGURE 4-9

571-0021

90°CLOCKWISEROTATION

OILMETERINGVALVE

MODULATINGMOTOR

GAS VOLUMECONTROL VALVE

FUEL UNIT

AIR INLETHOUSING ASSEMBLY

DECR.

DECREASE

INCREASE

INCREASE

DECREASE

INCREASE

INCREASE

DECREASE

571-0028

INCREASE RATE

DECREASE RATE

INCREASE RATE

DECREASE RATE

DEC.

INC.

DEC.

INC.

FIGURE 4-10

28

SECTION 5MAINTENANCE

A. GENERAL A maintenance program avoids unnecessary down time, costly repairs, and promotes safety . It is recommended that a record be maintained of daily, weekly, monthly, and yearly maintenance activities. See letter J.Electrical and mechanical devices require systematic and periodic inspection and maintenance. Any “automatic” features do not relieve the operator from responsibility, but rather free him from certain repetitive chores, providing time for upkeep and maintenance. Unusual noise, improper gauge reading, leak, sign of overheating, etc., can indicate a developing malfunction, requiring corrective action.

B. CONTROL SYSTEM Most operating controls require very little maintenance beyond regular inspection. Examine electrical connections. Keep the controls clean. Remove any dust from the interior of the control. Covers should be left on controls at all times. Keep the control cabinet doors closed. Dust and dirt can damage motor starters and relay contacts. Starter contacts are plated with silver and are not harmed by discoloration. Never use f les or abrasive materials such as sandpaper on contact points.

CAUTION

WARNING

WARNING

ONLY FACTORY AUTHORIZED BURNER SER VICE PERSONNEL SHOULD ST ART-UP, ADJUST, OR SERVICE THIS EQUIPMENT

Any cover plates, enclosures, or guards anchored to the burner, or any burner related equipment, must remain in position at all times. Only during maintenance and service shutdown can these cover plates, enclosures, or guards be allowed to be removed. They must be replaced, and securely anchored before testing, adjusting, or running the burner or burner related equipment.

PROGRAMMING CONTROL This control requires no adjustment, nor should any attempt be made to alter contact settings or timing logic. Those programmers with contacts may require occasional cleaning. If so, follow instructions given in the manufacturer’s bulletin. Never use abrasive materials. The manufacturer’s bulletin also contains troubleshooting information. The f ame detector lens should be cleaned as often as condi-tions demand. A periodic safety check procedure should be established to test the complete safeguard system. Tests should verify safety shutdown with a safety lock out upon failure to ignite the pilot or the main f ame, and upon loss of f ame. Each of these conditions should be checked on a scheduled basis. The safety check procedures are contained in the manufacturer’s bulletin.

MOTORS Supply voltage to the motor must not vary more than 10 percent from nameplate ratings. At initial start-up and regularly thereafter, check the motor current with an am-meter while the burner is in high f re position. If the reading exceeds the nameplate rating plus service factor, determine the cause and correct it. In dusty locations, clean the motor regularly to assure adequate cooling. Lubricate in accordance with the manufacturer’s instructions.

C. GAS SYSTEM Check the gas train for leaks. Check the gas valves and verify the low and high gas pressure settings.

SOLENOID VALVES A faint hum from the solenoid is normal when the coil is energized. Should the valve fail to operate, check that there is voltage at the valve coil. If there is no voltage at coil, check for loose wiring connections. If there is proper voltage at the valve coil and the valve still fails to open, replace the coil. Refer to manufacturer’s bulletin for correct procedure in coil replacement. Should it become necessary to replace the complete valve, be sure that the f ow is in the direction of the arrow on the valve body. Test for gas leaks and check valve action several times to ensure proper operation before attempting to relight burner.

MOTORIZED MAIN GAS VALVES Should the valve fail to operate, check for voltage at valve. Make certain that the main shut-off cock is closed prior to

WHEN REPLACING A CONTROL OR CLEANING CONTACTS, BE SURE TO DISCONNECT THE MAIN POWER SUPPL Y SINCE THE CONTROL IS ENERGIZED EVEN THOUGH THE BURNER SWITCH IS OFF. MORE THAN ONE DISCONNECT SWITCH MAY BE REQUIRED TO DISCONNECT ALL POWER.

CAUTIONAll power must be disconnected before servicing valves.

29

testing. The actuator is not f eld repairable nor should it be disassembled. Replace the actuator if valve fails to oper-ate. After replacement, cycle the valve with the fuel shut of f to determine that it opens and closes. If the valve has a visual indicator, observe its position for correct operation.

D. OIL SYSTEM Little maintenance is required on the oil systems other than cleaning the oil f lter. This procedure should be done at regular intervals. Increased inlet vacuum reading may indicate a clogged f lter. Follow the strainer manufacturer’s maintenance schedule. Maintenance checks on the f exible coupling between the fuel unit and motor for alignment, tightness and wear and oil piping connection tightness should also be made at regular intervals. You access the coupling by removing the airbox cover and loosening the two setscrews on the f ex coupling. The oil nozzle should be checked. Inside the nozzle lies a small screen that keeps out any particle not caught by the strainer. These particles will interfere with the normal oil f ow pattern exiting the nozzle. A distorted f ame can indicate a clogged nozzle. Inspect and clean the nozzle and screen. To clean the screen, swirler, and tip, unscrew the tip from the nozzle body. Clean nozzle parts in solvent. Never use wire or sharp metal tools to clean the nozzle orif ce. A metal tool will distort the ori f ce and ruin the nozzle. Reassemble the nozzle. The tailpiece must be screwed in with the swirler seating tight against the tip to ensure proper atomization. Reassemble the nozzle into the nozzle body. If a nozzle is replaced, it must be an identical nozzle (make, size and spray angle).

E. DRAWER ASSEMBLY The drawer assembly may be removed for inspection and service.1. Shut off burner, position switch in “OFF” position.2. Shut off all electric power to the burner.3. Disconnect the fuel lines from the drawer assembly access cover.4. After making note of where the bolts are located in relationship to the access cover slots, remove the drawer assembly access cover bolts. Pull the drawer partially out of the housing. Reach inside to disconnect the ignition cables from the electrodes for direct spark applications. Pull the drawer assembly completely out of the housing.5. To reinstall the drawer assembly, insert it part way into the housing, connect the ignition cables if applicable, and seat the assembly fully. Install the access cover bolts loosely . Slide the cover the original location, and tighten the bolts. Reconnect the fuel lines.

F. IGNITION ELECTRODE,CABLE AND PILOT Failure to keep electrodes clean and set in the proper position accounts for much faulty burner operation. Not only must the gap be correct, but the electrode points must be carefully located with respect to the nozzle. Sometimes

diff culty in securing the electrodes in their clamps can be corrected by using light metal shims around the porcelain. Defective or cracked porcelains require replacement to prevent short circuiting of the spark. A gradual wearing away of the electrode tips may require respacing of the points or replacement of the electrode. The pilot should be checked monthly for loosening of components and carbon buildup. Before removing the pilot, ensure that the fuel supply is shut off. On direct spark oil units, once you have removed the drawer assembly, check the electrode to nozzle gap and adjust if necessary. Refer to the drawer assembly drawings in the ADJUSTMENT section. For burners equipped with a gas pilot, the pilot is located on the side opposite to the main gas entrance. Close the gas pilot cock. Disconnect the pilot gas supply line. Remove the screws on the pilot access plate. Disconnect the high voltage ignition cable by pulling it straight back, away from the pilot assembly. The pilot gun assembly will slide back away from the f ame side of the burner. Once the pilot as-sembly is clear of the burner head bracket, turn the pilot assembly and retract it through the access hole. Inspect the electrode and adjust the gap if necessary. Thoroughly clean and adjust the porcelain insulated electrodes. Cor-rect all variations from the clearance dimensions. If the insulation on the high-voltage cables becomes cracked or charred, install new cables. Ignition cable should not be exposed to moisture, abrasion or rough handling. See that the connectors are in perfect contact with the cable ends. Unscrewing the snap portion of the connector will show whether this is true.

G. FLAME SCANNER The scanner must be clean. Even a small amount of contamination will reduce the f ame signal. Wipe the scanner lens with a clean soft cloth. Check pilot and f ame signal strength.

H. BURNER MOUNTING INSPECTION The seal between the burner f ange and furnace front plate must not permit combustion gases to escape. Periodic inspection is important. If leaking occurs, refer to Section INSTALLATION for proper sealing procedure.

I. EXTENDED SHUTDOWN When shutting down the burner for an extended period of time, the operator should use the following general guide-lines to protect the burner from its surrounding elements. This will add to the operating life of the burner:1. Turn the main electrical disconnect switch to the burner to OFF.2. Close all main fuel valves.3. If the burner operates in a damp environment, cover itwith plastic to protect all electrical components from mois-ture. 4. Remove the f ame safeguard and store in a dry atmo-sphere.

30

J. MAINTENANCE FLOW CHART RECOMMENDED TEST SCHEDULE

ITEM SER VICE BY REMARKS DAILY

Gauges, Monitors, Operator Make visual inspection and record readings in log. and Indicators

Instrument and Equipment Operator Make visual check against recommended specif cations. Settings

Low water, Fuel cut-off Operator Refer to instructions. and Alarms

WEEKLY

Firing rate control Operator Verify factory settings

Igniter Operator Make visual inspection. Check f ame signal strength.

Pilot and Main Fuel Valves Operator Open limit switch. Make audible and visual check. Check valve position indicators, and check fuel meters.

Flame Failure Controls Operator Close manual fuel supply for (1) pilot and (2) main fuel cock and/or valve(s). Check safety shutdown timing. Record in log.

Flame Signal Strength Operator Read and log the f ame signal for both pilot and main f ame. Notify Controls Service if readings are very high, very low, or f uctuating.

Linkages Operator Check all burner linkages for tightness. Tighten if required.

MONTHLY

Low Fan Pressure Operator Manually adjust until switch opens. Interlock

High and Low Gas Operator Refer to instructions. Manually adjust until switch opens. Pressure Interlocks

Scanner and Diffuser Operator Check, inspect and clean for soot buildup.

Pilot Assembly Operator Check for loosening of components, erosion or carbon buildup.

ANNUALLY

Strainer (Oil units) Operator Replace or clean the oil strainer element.

Impeller Operator Inspect and clean the combustion impeller.

Combustion Test Service Perform a complete combustion test. Adjust burner if necessary. Technician Read and Log data. Pilot turndown Test Service Required after any adjustment to f ame, scanner, or pilot Technician adjustment

Operating Controls Service Refer to instructions. Technician

31

TROUBLE SHOOTING PROBLEM SOLUTION

BURNER DOES NOT START 1. No voltage at program relay power input terminals. a. Main disconnect switch open. b. Blown control circuit fuse. c. Loose or broken electrical connection. 2. Program relay safety switch requires resetting. 3. Limit circuit not completed - no voltage at end of limit circuit program relay terminal. a. Pressure or temperature is above setting of operation control. b. Water below required level. Low-water light (and alarm horn) should indicate this condition. Check manual reset button, if provided, on low -water control. c. Fuel pressure must be within settings of low pressure and high pressure switches. d. Check burner air proving switch and high f re limit switch.

4. High or Low gas pressure - investigate and repair.

NO IGNITION 1. Lack of spark. a. Electrode grounded or porcelain cracked. b. Improper electrode setting. c. Loose terminal on ignition cable; cable shorted. d. Inoperative ignition transformer. e. Insuff cient or no voltage at pilot ignition circuit terminal. 2. Spark but no f ame. a. Lack of fuel - no gas pressure, closed fuel valve, empty tank, broken line b. Too much air f ow. c. No voltage to pilot solenoid. d. Defective pilot solenoid. e. Improperly positioned electrode (Direct spark models). 3. Low f re switch open in low f re proving circuit. a. Damper motor not closed, slipped cam, defective switch. b. Damper jammed or linkage binding. 4. Running interlock circuit not completed. a. Combustion proving switches defective or not properly set. b. Motor starter interlock contact not closed. 5. Flame detector defective, sight tube obstructed, or lens dirty.

SECTION 6

32

TROUBLE SHOOTING PROBLEM SOLUTION

PILOT FLAME, BUT NO MAIN FLAME

BURNER STAYS IN LOW FIRE

SHUTDOWN OCCURS DURING FIRING

1. Insuff cient pilot f ame. 2. Gas f red unit. a. Manual gas cock closed. b. Main gas valve inoperative. c. Gas pressure regulator inoperative. 3. Oil f red unit. a. Oil supply cut off by obstruction, closed valve, or loss of suction. b. Supply pump inoperative. c. No fuel. Broken, loose or missing oil pump coupling. d. Main oil valve inoperative. e. Check oil nozzle, gun and lines.

4. Flame detector defective, sight tube obstructed or lens dirty.

5. Insuff cient or no voltage at main fuel valve circuit terminal.

1. Pressure or temperature above modulating control setting. 2. Manual-automatic switch in wrong position. 3. Inoperative modulating motor. 4. Defective modulating control. 5. Binding or loose linkages, cams, setscrews etc.

1. Loss or stoppage of fuel supply. 2. Defective fuel valve; loose electrical connection. 3. Flame detector weak or defective. 4. Scanner lens dirty or sight tube obstructed. 5. If the programmer lockout switch has not tripped, check the limit circuit for an opened safety control.

33

TROUBLE SHOOTING

PROBLEM SOLUTION

SHUTDOWN OCCURS DURING FIRING (cont).

6. If the programmer lockout switch has tripped. a. Check fuel lines and valves. b. Check f ame detector. c. Check for open circuit in running interlock circuit. d. The f ame failure light is energized by ignition failure, main f ame failure, inadequate f ame signal, or open control in the running interlock circuit. 7. Improper air/fuel ratio. a. Slipping linkage. b. Damper stuck open. c. Fluctuating fuel supply. Temporary obstruction in the fuel line. Temporary drop in gas pressure.

8. Interlock device inoperative or defective.

9. Air in the oil lines. Bleed lines.

MODULATING MOTOR DOES NOT OPERATE

1. Manual-automatic switch in wrong position. 2. Linkage loose or jammed. 3. Motor does not drive to open or close during pre-purge or close on burner shutdown. a. Motor defective. b. Loose electrical connection. c. Damper motor transformer defective.

4. Motor does not operate on demand. a. Manual/automatic switch in wrong position. b. Modulating control improperly set or inoperative. c. Motor defective. d. Loose electrical connection. e. Damper motor transformer defective.

34

NOTES:

35

A. LIMITED WARRANTY The Company warrants that at the time of shipment, the equipment manufactured by it shall be merchantable, free from defects in material and workmanship and shall possess the characteristics represented in writing by the Company. The Company’s warranty is conditioned upon the equipment being properly installed and maintained and operated within the equipment’s capacity under normal load conditions with competent supervised operators. Equipment, accessories and other parts and components not manufactured by the Company are warranted only to the extent of and by the original manufacture’s warranty to the Company; In no event shall such other manufacturer’s warranty create any more extensive warranty obligations of the Company to the Buyer than the Company’s warranty covering equipment manufactured by the Company.

B. EXCLUSIONS FROM WARRANTY (I) THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, ORAL OR EXPRESS OR IMPLIED, INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION OF THE EQUIPMENT. THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE CONTAINED HEREIN TO THE EXTENT PERMITTED BY THE LAW. THERE ARE NO IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE. THE PROVISIONS AS TO DURATION, WARRANTY ADJUSTMENT AND LIMITATION OF LIABILITY SHALL BE THE SAME FOR BOTH IMPLIED WARRANTIES (IF ANY) AND EXPRESSED WARRANTIES. (II) The Company’s warranty is solely as stated in (a) above and does not apply or extend, for example, to: expendable item; ordinary wear and tear; altered units; units repaired by persons not expressly approved by the Company; materials not of the Company’s manufacture; or damage caused by accident, the elements, abuse, misuse, temporary heat, overloading, or by erosive or corrosive substances or by the alien presence of oil, grease, scale, deposits or other contaminants in the equipment.

C. WARRANTY ADJUSTMENT Buyer must make claim of any breach of any warranty by written notice to the Company’s home off ce within thirty (30) days of the discovery of any defect. The Company agrees at its option to repair or replace, BUT NOT INSTALL, F.O.B. Company’s plant, any part or parts of the equipment which within twelve (12) months from the date of initial operation but no more than eighteen (18) months from date of shipment shall prove the Company’s satisfaction (including return to the Company’s plant, transportation prepaid, for inspection, if required by the Company) to be defective within the above warranty. Any warranty adjustments made by the Company shall not extend the initial warranty period set forth above. Expenses incurred by Buyer in replacing or repairing or returning the equipment or any part or parts will not be reimbursed by the Company.

D. SPARE AND REPLACEMENT PARTS WARRANTY ADJUSTMENT The Company sells spare and replacement parts. This subparagraph (d) is the warranty adjustment for such parts. Buyer must make claim of any breach of any spare or replacement parts by written notice to the Company’s home off ce within thirty (30) days of the discovery of any alleged defect for all such parts manufactured by the company. The Company agrees at its option to repair or replace, BUT NOT INSTALL, F.O.B. Company’s plant, any part or parts or material it manufacture which, within one (1) year from the date of shipment shall prove to Company’s satisfaction (including return to the Company’s plant, transportation prepaid, for inspection, if required by the Company) to be defective within this part warranty. The warranty and warranty period for spare and replacement parts not manufactured by the company (purchased by the Company, from third party suppliers) shall be limited to the warranty and warranty adjustment extended to the Company by the original manufacturer of such parts; In no event shall such other manufacturer’s warranty create any more extensive warranty obligations of the Company to the Buyer for such parts than the Company’s warranty adjustment covering part manufactured by the Company as set forth in this subparagraph (d). Expenses incurred by Buyer in replacing or repairing or returning the spare or replacement parts will not be reimbursed by the Company.

warranty policy

36

E. LIMITATION OF LIABILITY The above warranty adjustment set forth Buyer’s exclusive remedy and the extent of the Company’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 LIABLE FOR ANY SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES OR FOR LOSS, DAMAGE OR EXPENSE, DIRECTLY OR INDIRECTLY ARISING FROM THE USE OF THE EQUIPMENT OR FROM ANY OTHER CAUSE WHETHER BASED ON WARRANTY (EXPRESS OR IMPLIED) OR TORT OR CONTRACT, and regardless of any advices or recommendations that may have been rendered concerning the purchase, installation, or use of the equipment.

37

START-UP / SERVICEREPORT

Test ConductedGAS OIL

Low 50% High Low 50% HighFiring Rate MMBtu / gph

Stack Temp (Gross) oF

Room Temp oF

O2%

CO2%

CO (PPM)

NOx (PPM)

Smoke (Bacharach)

Combustion Eff.%

Stack Draft "W.C.

Furnace Pressure "W.C.

Blast tube Pressure "W.C.

Steam Pressure PSIG

Water Temperature oF

Supply oil pressure PSIG

Return oil pressure PSIG

Vacuum oil pump "HG

Oil Temperature

Atom. air pressure

Gas Pressure @ Burner Inner Manifold

Manifold "W.C. Outer Manifold

Center Gas pressure "W.C.

Gas Pressure @ Regulator Inlet PSIG

Gas Pressure @ Regulator Outlet PSIG

Pilot Gas Pressure @ Regulator Outlet "W.C.

Flame Signal Main Low 50% High

Voltage AmperageElectric Motors L1 L2 L3 L1 L2 L3

Control VoltageBlower MotorAir CompressorAir-Oil or Metering

Adjusted by:

Date:

Accepted by:

(Signature Required)

The following information should be f lled in by the service technician at start-up or after any adjustment to the burner.

A copy of the start-up report MUST be returned to CB in order to validate the warranty of the burner.

Burner Model Serial Number Start-up Date

Control Checks Test Set PointLow Water Cut OffAux. LWCOHigh Water Cut OffOperating LimitHigh LimitOperating ControlStack Temp InterlockFlame FailureCombustion Air SwitchHigh Purge SwitchLow Fire InterlockOil Pressure SwitchOil Valve with P.O.C.InterlockHigh Gas Pressure SwitchLow Gas Pressure SwitchGas Valve P.O.C. InterlockPilot Turndown TestFlame Signal Pilot

(For Low NOx Burners)Blast Tube Temp. InterlockFGR Line Purge SwitchFGR Valve P.O.C. Switch

38

PRODUCT SATISFACTIONSURVEY

As a requirement of our ISO certif cation, please f ll-in this form and return to CB Prof re.Please rate your satisfaction with the following:

Delivery timeApperance of equipment after deliveryPiping and tubingWiringAll components arrived with equipmentEase of start-upPerformance of equipmentQuality of information provided Sales Engineering Service PartsOverall way any problems were handled

Burner Model Serial Number

Poor Good Excellent

Comments:

Date: By:

e-mail: [email protected] Address: http://www.cleaverbrooks.com

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