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IC-SA-1248 H Series Manual 9-2009

1. FLEX TUBE BOILER WATER LEG REFRACTORY FLOOR FIREBOX BOILER CAUTION GASKET MUST BE RESILIENT TO SEAL ANY UN EVEN AREAS BETWEEN THE BURNER FLANGE AND THE BOILER FRONT PLATE TO PREVENT LEAKAGE OF COMBUSTION GASES D BURNER INSTALLATION Prepare 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 Ifthey 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 CAST IRON SECTIONAL BOILER BOILER FRONT PLATE INSULATING ROPE GASKET BLAST TUBE MOUNTING FLANGE BURNER MOUNTING PLATE DOOR SUPPLIED WITH BOILER 5 BURNER BLAST TUBE 6 BURNER MOUTNING CLAMP 7 BOILER FLEX TUBES 8 CAST IRON SECTIONS 9 PACK WITH HIGH TEMPERATURE 10 CAST OR PLASTIC REFRACTORY 11 SMOKE BOX 12 BURNER BOILER ADAPTOR FLANGE 571 0011 FIGURE 2 5 3 Using insulating rope gasket wrap rope on the inside of the bolt circle looping rope around the four mounting studs 4 Se
2. pom 14111 Nope Control Checks ae O H Fiame Smoke omose I Base Reumoipese vacuum at pumps e items Romar pressure frame Sina Pe Gas Pressure Burner Inner Manifold Manifold W C Outer Manifold igh Purge Switch ow Fire Interlock il Pressure Switch Oil Valve with Interlock High Gas Pressure Switch Low Gas Pressure Switch Gas Valve P O C Center Gas pressure W C OM Gas Pressure Regulator Inlet PSIG Gas Pressure Regulator Outlet PSIG FGR Line P Switch Pilot Gas Pressure Regulator Outlet W C AD FGR Line Purge Switch i FGR Valve P O C Flame Signal Main Low 50 High Switch L3 Date Control Voltage j Blower Motor TT Accepted by Air Compressor J Air Oil or Metering Signature Required Blast Tube Temp Interlock 43 JF Industrial PRODUCT SATISFACTION Combustion uc SURVEY Burner Model Serial Number As a reguirement of our ISO certification please fill in this form and return to Industrial Combustion Please rate your satisfaction with the fo
3. 38 39 MODULATING MOTOR DOES NOT OPERATE 39 WARRANTY 41 42 START UP AND SERVICE 43 PRODUCT SATISFACTION SURVEY 44 OPERATING PRECAUTIONS This operating manual presents information that will help to properly operate and care for the eguipment 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 eguipment 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 Industrial Combustion 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 A 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 COMMISSION THIS EQUIPMENT INSTALLATION STARTU
4. 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 confirmed turn the burner switch OFF and let programmer finish 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 flame relay pulls in the slow opening motorized main gas valve is energized Slowly open the downstream manual shutoff gas cock Main flame should ignite at this time The gas valve and air damper continue advancing until high fire is reached Do not repeat unsuccessful light off attempts without rechecking burner and pilot adjustment Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt Set the gas low fire rate by adjusting butterfly valve and air linkage Referring to the adjustment section of this manual and using a combustion analyzer adjust the low fire ratio typical combustion analysis for low fire is 4 to 5 O2 Verify the minimum input rate by measuring the gas meter When low fire is adjusted shut down burner Restart sever
5. FAN HOUSING BACK CAP FUEL UNIT PRESSURE MOTOR RETURN FUEL UNIT 571 0003 FUECUNIT 571 0004 FIGURE 2 10 FIGURE 2 11 Low High Off Low High Low Oil System Size 2 H30 to H45 On Off Oil System Size 1 H10 to H25 SS 59 gt NOZZLE 3 4 NOZZLE PRESSURE Y A PRESSURE TAP 2 NC ud wr b OIL VALVES E FAN HOUSING FAN HOUSING FUEL UNIT BACK CAE BACK CAP lt PRESSURE MODUTROL MOTOR FUEL UNIT PRESSURE OIL NOZZLE FUEL UNIT 571 0006 SUPPLY 571 0005 METERING METERING VALVE VALVE FIGURE 2 12 FIGURE 2 13 Full Modulation Oil System Size 1 H10 to H25 Full Modulation Oil System Size 2 3 4 H30 to H125 Simplex Nozzle Return Flow Nozzle 17 OIL SUPPLY TANK 571 0016 OIL SUPPLY TANK 571 0018 RETURN TO TANK VALVE SUPPLY TO BURNERS BURNER NOZZLE OIL RETURN OIL INLET OIL RETURN OIL INLET METERING VALVE lil VALVE FILTER RETURN TO TANK a METERING FIGURE 2 14 BACK PRESSURE VALVE CHECK VALVE SUPPLY TO BURNERS SET BELOW 3 PSI BURNER NOZZLE Qim PRESSURE GAUGE D W ISOLATOR PRESSURE GAUGES W ISOLATORS VOLUME CONTROL BY PASS GATE VALVE OIL RETURN OIL INLET METERING VALVE FILTER BURNER
6. d FLAME FAILURE red illuminates when the flame safeguard system fails to detect pilot or main flame 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 flame direct spark models D FLAME SAFEGUARD CONTROLS The flame safeguard controls the operating sequence of the combustion system prepurge pilot firing and shutdown The flame safeguard programmer incorporates a flame sensing cell scanner to shut down the burner in the event of pilot flame or main flame failure Other safety controls shut down the burner based on sequence of operation as shown in the manufacturers flame safeguard manual E COMBUSTION AIR HANDLING SYSTEM 1 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 The damper is mechanically linked and actuated by the hydraulic cylinder for on off operation Low high off 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 combu
7. 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 atthe end ofthis section The size 2 HG 30 to 45 use a butterfly gas valve to control the gas flow 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 specifications The gas pressure required at the manifold is the pressure that is required to fire 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 30 or counterclockwise to decrease pressure 8 Turn the burner switch to the ON position 4 The burner will start and be in the low fire position 5 After a few seconds the O analyzer should have an accurate reading of the O present in the flue gas Nor mally O levels are set between 4 to 6 percent at low fire with less than 50 ppm CO To obtain the proper readings adjust the gas butterfly opening and air shutter Take note of the readings and pressures at the burner manifold and gas train 6 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water 7 Bring the burner to high fire position Adjust the
8. ACCESS COVER BLOWER IMPELLER FLEXIBLE 571 0020 COUPLING Figure 3 1 F NORMAL OPERATION Normal operation must be with the MANUAL AUTO switch selector at AUTO In automatic operation the operating cycle always pro ceeds sequentially through pre purge pilot ignition main flame 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 flame 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 flame outage low water current or
9. 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 roceeding 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 656 000036 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 flame safeguard control to close the safety switch contacts For LOW HIGH OFF or LOW HIGH LOW and FULL MODULATION models set the MANUAL AUTO switch to the MANUAL position Set the manual potentiometer to low fire position Open the gas pilot cock check pressure Normal setting is 3 to 6 WC when the pilot is burning
10. BAFFLE Size 2 HL 10 to 25 2 1 4 DIFFUSER FACE TO 571 0030 FRONT FACE OF AIR BAFFLE Size 2 HLG 10 to 25 Figure 4 4 27 3 1 8 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE 3 1 4 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE Size 3 HG 50 to 90 Size 4 HG 100 to 125 3 1 8 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE A 1 2 HOLD 571 0032 Size 3 HL 50 to 90 ad 571 0031 l As 3 1 8 DIFFUSER FACE TO FRONT FACE OF DIFFUSER Size 3 HLG 50 to 90 Figure 4 5 F PILOT TURN DOWN TEST For 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 pres sure gauge 0 10 w c or manometer is installed in the pilot line to monitor the pilot gas pressure 2 Whenthe pilotcomes on putthe programmertimer on pilot hold by placing the Run Test switch of the flame safeguard to the Test position Refer to the flame safeguard control manual instruc tions 3 Checkthe flame signal strength Adjustthe flame 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 unti
11. DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS OIL RETURN 557 0014 AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE 3 8 NPT NOTE Figure 1 9 H SIZE 4 INVERTED HOUSING ARRANGEMENT je 39 17 1 2 21 1 2 I GAS PILOT INLET 1 2 NPT Y 11 5 8 GAS PILOT INLET 4 HOLES 5 8 DIA 2 OIL INLET EQUALLY SPACED ON 16 1 2 Ma RETURN 21 5 8 A 15 3 8 B C OIL RETURN 26 5 8 3 8 NPT L 31 1 4 OIL INLET 3 8 NPT NOTE DIMENSION DIAGRAM THESE DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS H SERIES 100 120 AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE MODEL HL UPRIGHT SIZE 4 557 0039 Figure 1 10 10 SECTION 2 INSTALLATION A DRAFT CONDITIONS A boiler or other heating vessel fired with an H Series burner does not depend on chimney draft for proper combustion air Combustion air is supplied by the burner forced draft blower providing adeguate air for any normal combustion condition Since draft control is essential to maximum efficiency a draft regulator may be reguired when the vessel is con nected to a tall stack or where wind conditions may cause erratic draft Excessive furnace draft contributes to inefficient burner operation Sealed boilers may be operated under positive firebox 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
12. Fire position 3 Turn the burner switch to the ON position 4 The burner will start and be in the low fire position 5 Adjust low fire with the metering valve position to have approximately 80 to 90 PSI and adjust the low fire air shutter for a clean fire Record your combustion reading from the flue gas analyzer normally 8 to 11 percent CO and less than No 2 Smoke Bacharach 6 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water Then increase the fuel input to the boiler by turning the manual flame 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 CO CO Smoke and pressure readings Observe that your CO 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 and CO levels Continue to do this until the burner reaches high fire the potentiometer is at the OPEN position 8 Adjust the high fire fuel input to match maximum oil pressure At high fire 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 fire is typically 11 to 1
13. NOZZLE OIL RETURN OIL INLET OIL S METERING VALVE FILTER RELIEF VACUUM OR COMPOUND OIL GAUGE W ISOLATOR SUPPLY TANK GATE VALVE A CHECK VALVE 571 0017 STRAINER RELIEF VACUUM OR COMPOUND GAUGE W ISOLATOR TRANSFER PUMP STRAINER Typical Installation Using Day Tank 18 P a VALVE A TRANSFER PUMP BURNER NOZZLE FIGURE 2 15 METERING VALVE FIGURE 2 16 VACUUM BREAKER M MINIMUM Lens BURNER NOZZLE PRESSURE GAUGE OIL RETURN OIL INLET gt STRAINER OIL SUPPLY TANK GAIE STRAINER CHECK VALVE BURNER NOZZLE PRESSURE GAUGE OIL RETURN OILINLET METERING 2 METERING VALVE STRAINER VACUUM GAUGE W ISOLATOR VALVE E m STRAINER VACUUM GAUGE A 6 W ISOLATOR 571 0019 Typical Flooded Loop System G INSTALLATION CHECKLIST 1 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 fittings and unions c Tubing connections d Nuts bolts screws 2 Open all necessary oil shutoff valves Do not run pumps or fuel unit with
14. access hole Checkthe 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 CENTER ELECTRODE IN OPENING Ese ELECTRODE FLUSH W END OF TUBE 571 0025 8 3 4 Size 1 amp 2 Gas Pilot SET ELECTRODE TIP AT THE 9 00 O CLOCK POSITION 5 i 2 N ELECTRODE END WITHIN 1 4 FROM TUBE END TIP TO TUBE GAP OF 1 32 9 5 16 571 0026 Size 3 amp 4 Gas Pilot Figure 4 1 26 assembly 2 Rotate and slide each electrode in the clamp as neces sary to achieve the correct position relative to the burner tip 8 Tighten the locking screws securely to lock the electrode in position Apply a lock tight type compound to the screws before tightening 1 8 BETWEEN INNER EDGES OF THE ELECTRODES _ 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 diffuser clamp along th
15. air shutter settings for smooth ignition Re turn line oil pressure should be set according to Section 4 ADJUSTMENTS Do not repeat unsuccessful light off attempts without rechecking burner and pilot adjustment Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt Set the oil low fire 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 fire Typical combustion analysis for low fire is 4 0 to 6 5 O2 When low fire is adjusted shut down burner Restart several times to be sure the low fire 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 fire position This will cause the metering valve to close resulting in an increase in the oil pressure feeding the burner nozzle In high fire the oil metering valve should be in the fully closed position and the fuel oil pressure should be about 300 psi Check high fire at this point using combustion instruments High fire combustion analysis typically is 3 0 to 4 5 O2 Verify maximum inp
16. and ventilation purposes Fresh air supply must meet or exceed all code requirements Consult with insurance carrier and or local authorities for specific regulations WARNING THE BOILER ROOM PRESSURE MUST BE AT LEAST EQUAL TO THE OUTDOOR ATMO SPHERIC PRESSURE WHERE FAN VENTILA TION IS USED AIR MUST BE FORCED INTO THE BOILER ROOM NEVER EXHAUST AIR FROM THE BOILER ROOM ADJOINING AREAS HAVING EXHAUST FANS MUST BE POSITIVILY ISOLATED FROM THE BOILER ROOM C COMBUSTION CHAMBER DESIGN It is not possible to include a complete design and construction combustion chamber manual in this section but the following may be helpful in arranging burner ap plications in typical boilers Combustion chambers are of four basic types 1 Commercial Flex tubes watertube type boilers 2 Conventional Cast Iron sectional boilers 3 Conventional dry bottom firebox boilers having a refractory floor and full water walls 4 Full refractory combustion chambers in ash pit type installations where a complete firebox is required be low the level of the boiler water walls H burners are the forced draft flame retention type Refrac tory is required only to protect surfaces not adequately pro tected by free circulating water Four basic objectives 1 Provide adequate combustion space 2 Avoid flame impingement 3 Protect surfaces not adequately water cooled 4 Seal openings BURNER COMBUSTION CHAMBER MODEL LENGTH
17. fire 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 fire is typically 2 0 to 3 5 96 O2 with a target value of less than 50 ppm CO The burner should be adjusted to provide correct fuel flow at a constant rate as indicated on the burner data plate This is achieved by clocking the gas flow at the gas meter The gas utility or gas meter calibration data should be consulted to determine the correction factors to be ap plied to the meter Use the following formula to determine actual flow Gas Input HHV x Pgas x 520 x 3600 s x RATE Btu 29 92 Tgas 460 hr 5 hr Where HHV The higher heating value of the gas in Btu ft contact your local gas company for an exact measure ment Patm Atmospheric pressure in inches of mercury Pgas Gas pressure ahead of the volumetric flow meter in inches of mercury Tgas Gas temperature at the volumetric flow meter in Deg F RATE Natural gas rate taken with the volumetric flow meter in ft second 6 After completing all adjustments replace the regulator gaskets and slotted aluminum screw cap Tighten all linkages and marked settings Complete the Start up report at the end of this section OIL BURNERS On Off burners use the Suntec B2TC 8931 oil pump model High fire pressure adjustment is 200 300 PSI solenoid energized and low
18. high fire gas input to match maximum rating At high fire the but terfly 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 fire is typically 2 to 4 O 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 fire and high fire 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 fire pres sure adjustment is 100 200 PSI solenoid de energized High fire pressure adjustment is 200 300 PSI solenoid energized 1 Turn the burner switch to the ON position 2 Adjust low fire with the oil pressure regulating valve to have approximatly 100 to 200 PSI and adjust the air shutter for a clean fire Record your combustion reading from the flue gas analyzer normally 8 to 11 percent O 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 Operat
19. 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 firing 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 efficient 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 butterfly gas valve Model H30 45 low and high gas pressure switches Model H30 45 and air damper The auxiliary switch inside the M436 Mod motor makes or breaks the high fire gas See Fig 10 for switch adjustment The Low High Low boiler control energizes the M436 motor driving it to high fire When the boiler control denergize the M436 a built in return spring drives it to the low fire position The Size 1 HG 10 to 25 use a Honeywell V4944 two stage solenoid operated diaphragm valve No butterfly valve is used This valve uses two pressure regulators low fire and high fire and two solenoids to provide two distinct stages of pressure regulation High fire is obtained when the 2nd style solenoid is energized by the auxil
20. on off operation of the burner Adjust ments are made by matching the correct fuel air ratios 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 specifications The gas pressure required at the manifold is the pressure that is required to fire the burner at its rated capacity To adjust the regulator unscrew the cap located on top and turn the adjustment screw clockwise to increase pres Sure or counter clockwise to decrease pressure 28 3 Turn the burner switch to the ON position 4 Adjustthe burner for a smooth ignition ofthe main flame The bleed valve adjustment controls the opening of the V48 valve When the controller is not calling for heat the coil is de energized The plunger in the 3 way actuator is in the DOWN position so the bleed port is closed and the supply port is open Gas flows into the top part of the valve The gas pressure on top of the diaphragm the weight and the spring hold the valve closed On call for heat the controller contacts close and the coil is ener gized This pulls the plunger to the UP position opening the bleed port and closing the supply port The gas in the top of the valve flows out through the bleed port This reduces the pressure on top of the diaphragm allowing the gas pressure below to lift the diaphragm and open the valve 5 Adjust the high
21. s tct ertt ntt p 24 SECTION 4 ADJUSTMENTS A GENERAL erret 25 B COMBUSTION ADJUSTMENTS OIL AND GAS 25 C GAS PILOT 26 D DIRECT SPARK OIL PILOT ADJUSTMENT 26 E BURNER SETTINGS neni teas 26 PILOT TURN DOWN 28 ON OFF BURNER ADJUSTMENTS 28 LOW HIGH OFF BURNER ADJUSTMENTS 30 1 FULL MODULATION BURNER ADJUSTMENT S 31 PAGE SECTION 5 MAINTENANCE A teet 34 B CONTROL SYSTEM 5 rei ite t tue 34 C GAS SYSTEM eret denti etre 34 D Ole SYSTEM iin 35 E DRAWER ASSEMBLY 35 IGNITION ELECTRODE CABLE AND PILOT 35 3 tette 35 H BURNER MOUNTING 35 EXTENDED SHU TDONWN nete 35 J MAINTENANCE FLOW 36 SECTION 6 TROUBLE SHOOTING BURNER DOES NOT 37 aan 37 PILOT BUT NO MAIN 38 BURNER STAYS IN LOW 38 SHUTDOWN DURING
22. 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 4 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 eguipment THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEGUENTIAL DAMAGES OR FOR LOSS DAMAGE OR EXPENSE DIRECTLY OR INDIRECTLY ARISING FROM THE USE OF THE EGUIPMENT 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 eguipment 42 IP Industrial START UP SERVICE 11 Combustion REPORT The following information should be filled in by the service technician at start up or after any adjustment to the burner A copy ofthe start up report MUST be returned to IC in order to validate the warranty of the burner Burner Model Serial Number Start up Date oc Test Conducted Low 50 High Low 50 High Firing Rate MMBtu gph P Stack Temp Gross F_ P RoomTemp F J om
23. train prior to any initial commissioning or subseguent 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 eguipment back into service AN WARNING FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN EXPLOSION FIRE PROPERTY DAMAGE AND PERSONAL INJURY THIS PRO CEDURE MUST BE PERFORMED ONLY BY AUTHORIZED AND QUALIFED PERSONNEL e 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 flame 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
24. 0 ppm CO levels at all firing rates FUEL OIL ADJUSTMENTS Adjust for a clean fire Typically for No 2 oil O2 is 8 to 11 percent at low fire and 10 to 13 percent at high fire 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 HG HLG and HL 50 to 125 are equipped with a gas pilot system The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator Normal setting is 3 to 6 WC when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame Although it is possible to visibly ad just the size of the pilot flame obtain a proper DC volt or microamp reading of the flame signal The flame safeguard amplifier has a meter jack for this purpose Atinitial start up and during planned maintenance test the pilot flame signal pilot turndown and safety switch lockout Refer to the flame safeguard instruction manual N WARNING AN ULTRA VIOLET FLAME SENSOR ELECTRI CAL SPARK INTERFERENCE TEST MUST BE PERFORMED AFTER FINAL ADJUSTMENT SEE SECTION 3 OF THIS MANUAL FOR ADDITIONAL INFORMATION 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 HL 1
25. 0 to 45 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 diffuser and air baffle 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 diffuser 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 the burner 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 flame 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 complete assembly 5 For burners with a gas pilot Disconnect the pilot line and loosen the locking screws on the pilot access cover 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 and away from the diffuser Turn the assembly and retract itthrough the
26. 3 CO with less than No 2 smoke Ad just the high fire excess air rate using the high fire shutter adjustment 9 Modulate the burner to low fire Verify the readings once again The burner should be adjusted to provide correct fuel 32 flow at a constant rate at the low fire and high fire 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 Tum 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 first using oil because as a fuel oil has a greater combus tion airrequirementthan natural gas After being completely adjusted for oil combustion the burner is re started and adjusted using natural gas as fuel Combustion adjustment ofthe combination burner for natural gas involves balancing the input rate only against the existing flow 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 flame 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 de
27. GE WITHOUT NOTICE ES Rt Figure 1 6 BOLT PATTERN FOR H SIZE 1 INVERTED HOUSING ARRANGEMENT MOUNTING BURNER 4 3 8 16 x 1 1 2 LG STUDS ON A 12 1 2 B C FOR MOUNTING LUG USE MAIN GAS INLET 21 5 8 47 3 8 10 1 2 a 11 1 8 43 3 8 MAIN GAS INLET 1 1 2 NPT YA GAS PILOT GAS PILOT INLET INLET 1 2 OIL INLET amp RETURN 9 1 2 OIL INLET NOTE 1 4 NPT THESE DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS OIL RETURN 557 0030 AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE 1 4 NPT Figure 1 7 BOLT PATTERN FOR MOUNTING BURNER H SIZE 2 INVERTED HOUSING ARRANGEMENT 4 3 8 16 x 1 1 2 LG STUDS ON A 14 B C FOR MOUNTING LUG USE MAIN GAS INLET 22 3 4 10 7 8 11 7 8 MAIN GAS INLET 2 NPT GAS PILOT INLET 1 2 NPT E 5 AT bz e GAS PILOT INLET OIL INLET amp RETURN OIL INLET 1 4 NPT THESE DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS OIL RETURN 557 0034 AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE 27 1 4 NPT Figure 1 8 MOUNTING BURNER PORT PATTERNIEOR H SIZE 3 INVERTED HOUSING ARRANGEMENT 19 3 4 R 4 3 8 16 x 1 1 2 LG STUDS ON A 16 1 2 DIA B C FOR MOUNTING LUG USE MAIN GAS INLET MAIN GAS INLET 2 1 2 NPT GAS PILOT INLET 1 2 NPT GAS PILOT INLET OIL INLET amp RETURN OIL INLET 3 8 NPT THESE
28. H SERIES Installation Operation and Service Manual Industrial Combustion WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SERVICE THIS EGUIPMENT 1248 09 09 H SERIES TABLE OF CONTENTS PAGE SECTION 1 INTRODUCTION A GENERAL 3 B DESCRIPTION iiiter eet taper attente en 3 C OPERATING 3 D FLAME SAFEGUARD CONTROLS sss 3 E COMBUSTION AIR HANDLING SYSTEM 4 Fs Oll SYSTEM itu teer eriperet etes 4 PILOT SYSTEM trente ttn 4 H GAS SYSTEM 5 ect o eee 4 SECTION 2 INSTALLATION A DRAFT CONDITIONS sss 11 B COMBUSTION AIR SUPPLY 11 C COMBUSTION CHAMBER DESIGM 11 D BURNER 13 E GAS PIPING itte te iere de dans 14 FUEL OIL PIPING cn etu ees 14 INSTALLATION 19 SECTION 3 STARTING AND OPERATING A PREPARATION FOR INITIAL START UP 20 B FIRING PREPARATIONS 20 C SEQUENCE OF 21 D ELECTRICAL INTERFERENCE TEST 21 E START UP AND 22 NORMAL OPERATION 24 G SBUTDOWDN
29. IPMENT The following test equipment should be used to set up and adjust the burner correctly k Combustion analyzer with O2 indication 2 U Tube manometer or pressure gauge to measure gas pressures Main and Pilot Vacuum and pres sure gauges for oil 3 Inclined manometer to measure draft pressures 4 Smoke spot tester for oil burners and CO analyzer for gas fired units 5 Voltmeter Ammeter 6 Stack Thermometer and Thermocouples AIR FLOW ADJUSTMENTS The H Series burners have a unique air shutter design that enables precise independent air flow rate adjustments for both the high fire and low fire 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 NOTE THE ON OFF 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 The modulating main air shutter regulates the flow of inlet air through the fan at flow rates between high fire and low fire conditions according to the modulating motor position One non modulating air shutter for high fire combustion air control is adjusted to provide the correct amount of air while the system is operating at high fire fuel input rate with the main air shutter fully open The other non modulating shutter for low fire combustio
30. ONLY SPECIFICATIONS MODELS HL amp HLG SIZE 2 AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE 557 0003 Figure 1 4 BOLT PATTERN FOR MOUNTING BURNER 19 3 4R MAIN GAS 4 3 8 16 x 1 1 2 LG STUDS ON A 16 1 2 DIA B C GAS PILOT FOR MOUNTING LUG USE INLET 1 2 NPT 31 7 8 16 1 4 15 5 8 GAS PILOT 75 8 MAIN GAS a T INLET 2 1 2 NPT OIL INLET OILINLET 3 8 NPT amp RETURN 25 7 8 28 3 8 DIMENSION DIAGRAM QOLRETURN _ H SERIES 50 55 60 70 80 amp 90 NOTE 3 8 NPT MODELS HL amp HLG SIZE 3 THESE DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS 557 0001 B AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE Figure 1 5 MAIN GAS INLET 19 3 4R 4 HOLES 5 8 DIA EQUALLY SPACED ON A 15 3 8 B C GAS PILOT INLET 1 2 NPT j E 20 17 3 8 GAS PILOT INLET 11 1 2 i 37 3 8 1 dr MAIN GAS INLET 10 5 8 MAIN GAS ja 1 INLET 2 1 2 NPT OIL RETURN 3 8 NPT 265 8 10 OIL INLET OIL INLET 31 4 3 8 NPT 16 12 amp RETURN 34 DIMENSION DIAGRAM NOTE H SERIES 100 120 THESE DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS MODEL HL amp HLG AND DIMENSIONS ARE SUBJECT TO CHAN
31. Optional Low High Off Low High Low Full Modulation SIZE 2 H30 45 Low High Off Optional Low High Low Full Modulation SIZE 3 H50 90 Full Modulation SIZE 4 H100 125 Full Modulation C OPERATING CONTROLS PANEL The control panel contains a flame 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 firing fuel Off position Burner off Oil position Selects oil as the firing 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 firing 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
32. P OPERATION AND MAINTE NANCE OF THIS EQUIPMENT MUST BE PERFORMED ONLY BY FACTORY AUTHORIZED EXPERIENCED AND QUALIFIED PERSONNEL A WARNING 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 A WARNING TO AVOID PERSONAL INJURY FROM MOVING PARTS SHUT OFF ALL ELEC TRICAL POWER BEFORE SERVICING THIS EQUIPMENT CAUTION ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SERVICE THIS EQUIP MENT READ PRODUCT MANUAL AND FULLY UNDERSTAND ITS CONTENTS BEFORE ATTEMPTING TO OPERATE THIS EQUIP MENT SERIOUS PERSONAL INJURY OR DEATH MAY RESULT CAUTION PROVIDE SUPPORT FOR THIS PANEL TO PREVENT DAMAGE TO THE ELEC TRICAL COMPONENTS CAUTION AFTER FINAL FUEL INPUT ADJUST MENTS ARE MADE VERIFY FUEL IN PUT BY METER IF POSSIBLE Further warning and caution references have been made in this manual and should be adhered to for RATED BURNER INPUT smooth operation of the burner MBTU HR USGPH 10 1 000 7 1 This symbol precedes information 1250 9 0 JAN WARNING which if disregarded may result in injury to the user of the burner 1 500 10 7 or to others 1 680 12 0 This symbol precedes information 2 000 14 3 CAUTION which if disregarded may result 2 100 15 0 in damage to the burner 2 500 17 8 This symbol precedes information 3 000 21 4 NOTE which is vital to the op
33. RNER THE H 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 CRANKASE OIL OR ANY OIL CONTAINING GASOLINE SECTION 1 INTRODUCTION A GENERAL INFORMATION Industrial Combustion H Series burners are assembled wired and tested at the factory They are listed by the Un derwriters Laboratory cUL CSD 1 I R I F M and other regulatory agency control options are available Optional controls and control systems are also available The operator of this eguipment 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 CAUTION ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SERVICE THIS EQUIPMENT B DESCRIPTION The Industrial Combustion H Series burners are designed to operate with gas and light oil H burners are specifically designed to operate in cast iron firebox or commercial watertube 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 configuration SIZE 1 H10 25 On Off
34. SCRIPTION 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 M The Company s warranty is solely as stated 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 office 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 ab
35. ST BE UPSTREAM OF THE MAIN GAS PRES SURE REGULATOR GAS PILOT TRAIN GAS BUTTERFLY VALVE OIL METERING VALVE OIL PUMP AIR HOUSING 571 0001 Figure 1 1 GAS MANIFOLD DIFFUSER AIR BAFFLE MOUNTING FLANGE MAIN GAS INLET NOZZLE BODY amp TIPS AXIAL GAS SPUD RADIAL 557 0002 GAS SPUD Figure 1 2 BOLT PATTERN FOR MOUNTING BURNER 4 3 8 16 x 1 1 2 LG STUDS ON A 12 1 2 FOR MOUNTING LUG USE GAS PILOT _INLET 1 27 NPT Pp 27 1 2 10 1 2 4 17 MAIN CAS INLET 1 1 2 NPT 24 1 2 211 INLET D INLET 3 8 NPT 8 1 8 RETURN 26 1 8 ol Olt RETURN 26 1 8 v 3 8 DIMENSION DIAGRAM THESE DIMENSIONS ARE FOR REFERENCE ONLY SPECIFICATIONS H SERIES 10 15 20 amp 25 AND DIMENSIONS ARE SUBJECT TO CHANGE WITHOUT NOTICE MODEEHESIHEGESIZE LOW HIGH LOW LOW HIGH OFF 557 0021 Figure 1 3 BOLT PATTERN FOR MOUNTING BURNER MAIN GAS INLET 4 3 8 16 x 1 1 2 LG STUDS ON A 14 B C FOR MOUNTING LUG USE GAS PILOT INLET 29 1 4 a 12 7 8 16 3 8 5 1 2 GAS PILOT INLET i MAIN GAS INLET 2 NPT OIL INLET 3 8 NPT OIL INLET amp RETURN OIL RETURN 3 8 NET DIMENSION DIAGRAM NOTE H SERIES 30 35 40 amp 45 THESE DIMENSIONS ARE FOR REFERENCE
36. WIDTH CL HEIGHT SS eb mST 1 Tala 04 0 ed ID cs a ee me CO oo oda oo 5 19191919 M m m S Figure 2 1 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 modifications to suit some conditions Factors such as fuel properties total combustion volume length of flame travel often make fixed reguirements impractical When in doubt consult the fac tory Insulation should be provided between the refractory and the boiler base Mineral wool or other material not likely to settle is preferred The chamber front wall may be constructed of firebrick or insulating firebrick Insulation should be used between refractory and front plate Fire brick or insulating firebrick should be set in high tempera ture bonding mortar with provision for expansion 11 a I a z 4 gt m E a a a gt o FIGURE 2 2 Cast Iron Boiler 571 0010 SUPPORT BURNER HERE FIGURE 2 3 Firebox Boiler 571 0007 z m a o a a 3 a FIGURE 2 4 Commercial Watertube 2 1
37. al times to be sure the low fire 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 fire position Check high fire at this point using combustion instruments High fire combustion analysis typically is 2 0 to 3 5 O2 Verify maximum input rate by measuring the gas meter Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate settings CO levels should be less than 50 ppm on an air free basis at all firing rates 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 flame 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 flame detector proves the presence of a satisfactory pilot the programmer will proceed to main flame ignition Make initial
38. ame appearance although it may help in making preliminary settings The proper settings of air fuel ratios must be determined by flue 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 2 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 definitively show whether sufficient air has been provided for combustion STACK TEMPERATURE Net stack temperature is obtained by subtracting the ambient temperature from the flue gas temperature Ahigh net stack temperature indicates wasted heat Decreasing either the temperature or the volume of the flue gas or both can reduce stack heat loss Flue gas temperature is reduced by improving heat transfer or by reducing excess combustion air Acertain amount of excess air is necessary to complete combustion More efficient 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 insufficient draft improper fuel viscosity improper fuel air ratio excessive air leaks in the combustion chamber or improper fuel oil temperature TEST EQU
39. be made to alter contact settings or timing logic Those programmers with contacts may require occasional cleaning Ifso follow instructions given in the manufacturer s bulletin Never use abrasive materials The manufacturer s bulletin also contains troubleshooting information The flame detector lens should be cleaned as often as condi tions demand Aperiodic 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 flame and upon loss of flame 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 fire 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 valv
40. e 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 flow 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 CAUTION All power must be disconnected before servicing valves 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 34 testing The actuator is not field repairable nor should it be disassembled Replace the actuator if valve fails to oper ate After replacement cycle the valve with the fuel shut off 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 reguired on the oil systems other than cleaning the oil filter This procedure should be done at regular intervals Increased inlet vacuum reading may indicate a clogged filter Follow the strainer manufacturer s maintenance schedule Maintenance checks on the flexible coupling between the fuel unit and motor for alignment tightness and wear and oil piping connection tightness should al
41. e 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 7 16 FROM CENTER OF NOZZIE 5 To BOTTOM LEDGE OF THE Zu RODES 1 4 FROM NOZZLE TIPS TO OUTER EDGE OF THE ELECTRODES 571 0027 Direct spark ignition Figure 4 2 Measure the position of the diffuser to air baffle and compare tothe following drawer assembly drawings Adjust as follows 1 Measurethe distance betweenthe leading edge of the diffuser and the front face of the inner ring on the air baffle 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 1 11 16 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE Size 1 HG 10 to 25 5 8 Hop 1 11 16 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE Size 1 HL 10 to 25 1 11 16 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE 571 0029 Size 1 HLG 10 to 25 Figure 4 3 2 1 4 DIFFUSER FACE TO FRONT FACE OF AIR BAFFLE Size 2 HG 10 to 25 11 16 HOLD 2 1 4 DIFFUSER FACE TO FRONT FACE OF AIR
42. e the boiler at low fire until it is up to operating pressure steam or temperature hot water 4 Adjust the high fire fuel input to match maximum oil pressure At high fire the pressure should be 300 PSI Verify and record your readings and pressures High fire is typically 11 to 13 CO with less than No 2 smoke The burner should be adjusted to provide correct fuel flow at aconstant rate at the low fire and high fire 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 first 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 flow 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 defined in the Oil Burners section 4 After the system has been completely adjusted for oil firing place the burner switch OFF and
43. ective sight tube obstructed or lens dirty 5 Insufficient or no voltage at main fuel valve circuit terminal Buen STAYS IN LOW 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 SHUTDOWN OCCURS 1 Loss or stoppage of fuel supply DURING FIRING 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 38 TROUBLE SHOOTING PROBLEM SOLUTION SHUTDOWN OCCURS 6 If the programmer lockout switch has tripped DURING FIRING cont a Check fuel lines and valves b Check flame detector c Check for open circuit in running interlock circuit d The flame failure light is energized by ignition failure main flame failure inadequate flame 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 1 Manual automatic switch in wrong position DOES NOT OPERATE 3 Motor does not drive to open
44. equires manual reset after being tripped 6 LOW GAS PRESSURE SWITCH Models 30 125 Apressure 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 flows through the main gas shutoff cock through the pressure regulator to the automatic gas valves and butterfly valve to the gas manifold The butterfly gas valve modulates flow to burner input demand The but terfly 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 CONTROL PANEL IGNITION TRANSFORMER DRAWER ASSEMBLY COVER SCANNER BLOWER MOTOR OIL SOLENOID VALUE MODULATING MOTOR Anormally 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 TRAIN COMPONENTS UP STREAM OF THE BUTTERFLY VALVE ARE SHIPPED LOOSE TO BE MOUNTED BY THE INSTALLER PILOT GAS SUPPLY CONNECTION MU
45. eration or 3 360 24 0 maintenance of the burner 3 500 25 0 Model designations are based on the type of fuel s to 4 000 28 6 be fired and the amount of furnace pressure to be over d 4 200 30 0 come Burner size is based firing rate rated input BTU HR 4 500 32 1 5 000 35 7 FUEL ATOMIZATION 5 250 37 5 5 500 39 3 2 OIL PRESSURE 6 000 42 9 EXAMPLE Model number on nameplate is 7 000 90 0 HLG 45 indicating it is a combination No 2 oil and Gas 8 000 57 1 burner with input rated at 4 500 MBTU per hour against 8 400 60 0 furnace pressures up to 1 0 W C 9 000 64 3 BURNER SIZE AND RATED FURNACE PRESSURE 10 000 71 4 H BURNER 10 500 75 0 SIZE 1 H10 to 25 0 75 W C SIZE 2 H30 to 45 1 0 W C ee oe SIZE 3 H50 to 90 2 0 W C 12 000 85 7 SIZE 4 H100 to 120 3 0 W C 12 600 90 0 Gas input based on natural Gas at 1 000 Btu cu ft and 0 60 specific gravity Oil input based on 140 000 Btu gal Refer to burner nameplate data for correct manifold pressures 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 OILAND GAS BURNING EQUIPMENTS SHALL BE CONNECTED TO FLUES HAVING SUFFICIENT DRAFT AT ALL TIMES TO ASSURE SAFE AND PROPER OPERATION OF THE BU
46. fined in the Oil Burners section 6 After the system has been completely adjusted for oil firing place the burner switch OFF and position the fuel selector switch to GAS 7 Proceed with start up and adjustments using the same procedures defined in the Gas Burners section Do not alter the air settings set for oil Correct your O levels by adjusting the butterfly valve O MAIN AIR SHUTTER SHOWN IN LOW FIRE POSTION HIGH FIRE HIGH FIRE AIR SHUTTER W INDICATOR FIGURE 4 7 571 0023 TYPICAL LOCATION OF THE POINTER WHEN AT HIGH FIRE CLOSED 571 0022 FIGURE 4 8 INCREASE GAS VOLUME CONTROL VALVE DECREASE MODULATING DECREASE INLET HOUSING ASSEMBLY 571 0021 FIGURE 4 9 INCREASE RATE DECREASE RATE 571 0028 FIGURE 4 10 SECTION 5 MAINTENANCE 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 H 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
47. fire pressure adjustment is 100 200 PSI solenoid de energized 1 Briefly push in the starter contact and release to ensure that the blower motor and oil pump are rotating in the correct direction 2 Turn the burner switch to the ON position 3 Make sure a pressure gauge 0 600 PSI range is in stalled downstream of the solenoid valves Adjust the burner for a smooth ignition of the main flame Discon nect the wiring to the solenoid on the Suntec B2TC 8931 oil pump Loosen and remove knurled nut on the sole noid Adjust the screw clockwise to increase low fire oil pressure and counterclockwise to decrease the low fire oil pressure until a smooth ignition of the oil flame is obtained and a satisfactory low fire oil flame is established Turn burner off and restart to ensure smooth ignition is obtained at the set low fire pressure Replace knurled nut and tighten finger tight 4 Adjust the high fire oil input to match the maximum rat ing Turn the burner off and reconnect the wiring to the solenoid valve Restart the burner and allow burner to go through ignition and low fire When the solenoid energizes the oil pump discharge pressure is at high fire pressure The high fire pressure adjustment screw is located on the oil pump body Adjust the screw clockwise to increase the pressure and counterclockwise to decrease the pressure until correct amount of oil pressure is obtained The high fire oil pressure should be 300 PSI High f
48. 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 flame 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 firing 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 24 SECTION 4 ADJUSTMENTS 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 reguire further adjustment after installation to assure maximum operating efficiency 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 Acombustion efficiency 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 Efficient combustion cannot be properly judged by fl
49. gas train consists of a manual shutoff cock a gas pressure regulator and a solenoid operated gas shutoff valve H GAS HANDLING SYSTEM Depending 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 COMPONENTS 1 GAS VOLUME VALVE The butterfly type valve is po sitioned by linkage from the modulating motor and controls the rate of flow 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 10 25 Diaphragm gas valve and one safety solenoid valve Models 30 50 One motorized gas valve w proof of closure Models 55 120 One motorized gas valve w proof of closure and one safety solenoid valve 3 MAIN GAS REGULATOR Regulates gas train pressure to specified pressure required at the burner manifold Input is set by main gas pressure regulator adjustment 4 MAIN GAS COCKS Used for manual shutoff of the gas supply upstream of the pressure regulator A second shutoff cock downstream of the main gas valve s provides means of testing for leakage through the gas valve s 5 HIGH GAS PRESSURE SWITCH Models 30 125 Apressure 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 r
50. 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 firing 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 filter 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 baffle components must be correctly set The air damper blades must be adjusted relative to the established flow rates to provide the correct amount of air for complete efficient 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 flow rates are individually adjusted at low fire and a
51. gauge reading leak sign of overheating etc can indicate a developing malfunction reguiring corrective action N WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SERVICE THIS EQUIPMENT CAUTION 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 mustbe replaced and securely anchored before testing adjusting or running the burner or burner related equipment 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 ofthe 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 files or abrasive materials such as sandpaper on contact points A WARNING WHEN REPLACING A CONTROL OR CLEANING CONTACTS BE SURE TO DISCONNECT THE MAIN POWER SUPPLY SINCE THE CONTROL IS ENERGIZED EVEN THOUGH THE BURNER SWITCH IS OFF MORE THAN ONE DISCONNECT SWITCH MAY BE REQUIRED TO DISCONNECT ALL POWER PROGRAMMING CONTROL This control requires no adjustment nor should any attempt
52. h 4 High or Low gas pressure investigate and repair 1 Lack of spark a Electrode grounded or porcelain cracked b Improper electrode setting Loose terminal on ignition cable cable shorted d Inoperative ignition transformer e Insufficient or no voltage at pilot ignition circuit terminal BURNER DOES NOT START NO IGNITION 2 Spark but no flame a Lack of fuel no gas pressure closed fuel valve empty tank broken line b Too much air flow c No voltage to pilot solenoid d Defective pilot solenoid e Improperly positioned electrode Direct spark models 3 Low fire switch open in low fire 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 37 TROUBLE SHOOTING PROBLEM SOLUTION PILOT FLAME BUT NO 1 Insufficient pilot flame MAIN FLAME 2 Gas fired unit a Manual gas cock closed b Main gas valve inoperative c Gas pressure regulator inoperative 3 Oil fired 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 def
53. iary 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 specifications The gas pressure required at the manifold is the pressure that is required to fire 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 Setthe thermostat or control to energize the V4944 valve and check final outlet pressure Allow enough time for the pressure to stabalize valve outlet pressure measurements are made at a point approximately five pipe diameter downstream from the valve outlet Low fire outlet range is 0 85 wc to 2 0 wc for natural gas and high fire outlet range is 3 wc to 4 5 we 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 analyzer should have an accurate reading of the O presentin the flue gas Normally O levels are set between 4 to 6 percen
54. ire is typically 3 596 to 4 5 O2 with less than a No 1 smoke The burner should be adjusted to provide the correct amount of fuel flow at a constant rate at high fire position as indicated on the burner data plate located inside the control panel COMBINATION GAS OIL BURNERS In general the combination fueled system is to be started first using oil because as a fuel oil has a greater combus tion airrequirementthan natural gas After being completely adjusted for oil combustion the burner is re started and adjusted using natural gas as fuel Combustion adjustment ofthe combination burner for natural gas involves balancing the input rate only against the existing flow 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 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 usingthe same procedures defined in the Oil Burners section 4 After the system has been completely adjusted for oil firing place the burner switch OFF and position the fuel selector switch to GAS 5 Proceed with start up and adjustments using the same procedures defined in the Gas Burners section Do not alter the air settings set for oil 29 H LOW HIGH OFF 8 LOW HIGH LOW BURNER ADJUSTMENTS Refer to the burner data plate located inside the control panel door The nameplate will
55. l the scanner looses sight of the flame and give a flame lock out than reset the adjust ment to normal level Note the minimum pressure level 5 After adjusting the pressure backto normal level setthe programmer to the Run position Main flame will come on and the burner is in the low fire position 6 Start and stop the burner several times to ensure proper pilot setting G ON OFF BURNER ADJUSTMENTS Refer to the burner data plate located inside the control Figure 4 6 Maximum 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 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 firing 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 efficient combustion Refer to the boiler instruction manual for the boiler controls settings GAS BURNERS On Off gas burners are typically equipped witha pres sure regulator and a solenoid operated diaphragm gas valve to control the
56. lator specifications The gas pressure required at the manifold is the pressure that is required to fire the burner at its rated capacity To adjust the regulator unscrew the cap located on top and turn the adjustment screw clockwise to increase pres sure or counter clockwise to decrease pressure 3 Set the Manual Auto switch on the Manual position 4 Position the manual flame 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 fire position 7 After a few seconds the O analyzer should have an ac 31 curate reading of the O present in the flue gas Normally O levels are set between 4 and 6 percent at low fire with less than 50 ppm CO To obtain the proper readings adjust the gas butterfly opening and low fire air shutter Take note of the readings and pressures at the burner manifold and gas train 8 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water Then in crease the fuel input to the boiler by turning the manual flame control potentiometer towards OPEN in small increments This will cause the butterfly 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 O CO and pressure readings Observe that your O and CO levels remain within an acceptable limit Adjust the pressure regulator as necessary
57. lements 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 it with plastic to protect all electrical components from mois ture 4 Remove the flame safeguard and store in a dry atmo sphere 35 J MAINTENANCE FLOW CHART RECOMMENDED TEST SCHEDULE ITEM SERVICE BY REMARKS DAILY Operator Make visual inspection and record readings in log Instrument and Eguipment Operator Make visual check against recommended specifications Low water Fuel cut off Operator Refer to instructions and Alarms WEEKLY Operator Verify factory settings Operator Make visual inspection Check flame signal strength Operator Open limit switch Make audible and visual check Check valve position indicators and check fuel meters Gauges Monitors and Indicators Co 5 Firing rate control Igniter Pilot and Main Fuel Valves 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 flame signal for both pilot and main flame Notify Controls Service if readings are very high very low or fluctuating Linkages Operator Check all burner linkages for tightness Tighten if required MONTHLY Low Fan Pressure Operator Manually adjust
58. lications 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 difficulty 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
59. llowing Poor Good Excellent Delivery time time ee ee of equipment after delivery Piping and tubing Wiring All components arrived with equipment GST RS ERE P Ease of start up Performance of equipment of information provided Overall way any problems were handled Comments Date By 44
60. mit 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 flame 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 flame 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 nectthe 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 flame relay should not pull in Upon completion of successful test disconnect power supply Reconnect oil safety shutoff valve and turn on manual pilot gas valve Reconnect power supply and proceed with start up procedures 2 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 shutoff valves located in the main gas
61. n air control is adjusted to provide the correct amount of air with the system operating at low fire input rate with the main shutter completely closed COMBUSTION SETTINGS Fuel and air flow rates are individually adjusted at low fire and at high fire to achieve rated input firing rate turndown optimum efficiency safe operation and the ability to cope with environmental changes including air temperature humidity barometric pressure and fuel property changes Turndown capability for oil is less than that for gas due to the excess air reguirement 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 flue gas are used to optimize combustion efficiency excess air and unburned 25 fuel The system should be adjusted to the minimum excess air guantity that provides low levels of unburned fuel with sufficient 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 fire combustion analysis typically is 6 to 9 percent 2 and less than 04 percent CO 400 ppm High fire reading typically is 9 to 10 5 percent O2 and less than 04 percent CO The H Series burners are capable of operat ing at low excess air and less than 5
62. n inches of mercury Tgas Gas temperature at the volumetric flow meter in Deg F RATE Natural gas rate taken with the volumetric flow meter in ft 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 Theoilburner adjustments consistofthe oil metering valve and air shutters The firing rate is regulated by a metering valve in the nozzle return line At low fire the arrow on the valve points to approximately number 7 and at high fire it is in the closed position no return flow 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 fire is approximately 80 to 100 PSI and 300 PSI at high fire Size 1 H10 to 25 uses a simplex nozzle sizes 2 3 and 4 use a return flow nozzle 1 Set the Manual Auto switch on the Manual position 2 Position the manual flame control potentiometer in the CLOSED Low
63. n 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 firing Refer to Section E for starting and operating information OIL BURNERS Prior to initial firing oil flow and pressure should be veri fied 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 verified 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 flow This might be caused by obstruction in the suction line excessive lift inadequate priming suction line leaks etc Until oil flow is established avoid prolonged operation of the pump If oil flow is not established after a second priming investigation is required 20 A vacuum or compound pressure vacuum
64. 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 29 NOTES 40 Industrial Combustion uc Warranty policy 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 1 THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES ORAL OR EXPRESS OR IMPLIED INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE DE
65. out oil 3 Before connecting electrical current to any component be sure the voltage is the same as that specified on com ponent nameplates 4 Before burner operation be sure all motors are rotating in the proper direction 5 Before firing make sure the burner firing head and dry areas of the boiler are protected with refractory The burner mounting flange 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 GATE VALVE TRANSFER PUMP TRANSFER PUMP DUPLEX PUMP SYSTEM FIGURE 2 17 CAUTION BEFORE OPENING THE MANUAL GAS SHUT OFF VALVES READ THE REGULA TOR INSTRUCTIONS CAREFULLY 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 DO NOT EXCEED THE REGU LATOR PRESSURE RATINGS 19 SECTION 3 STARTING 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 drawing
66. ove 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 office within thirty 80 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
67. ped gph b Length of suction line feet c Diameter of the suction line d Number of fittings 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 flow 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 14 a typical installation showing separate suction lines for each burner with a common return line Figure 2 15 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 16
68. position the fuel selector switch to GAS 5 Proceed with start up and adjustments using the same procedures defined in the Gas Burners section Do not alter the air settings set for oil Correct your O levels by adjusting the butterfly valve for Size 2 models and the regulators low and high pressures for Size 1 models 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 firing 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 efficient 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 butterfly gas valve low and high gas pressure switches Model H30 120 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 regu
69. s and contents of Section 1 Adjustment procedures given in Sec tion 4 should be reviewed prior to firing 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 specifications 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 flame safeguard control chassis is shipped unmounted Check all screw connec tions before attaching flame 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 momen
70. 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 flame 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 flame signal Wipe the scanner lens with a clean soft cloth Check pilot and flame signal strength H BURNER MOUNTING INSPECTION The seal between the burner flange 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 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 e
71. shows an installation using a day tank A pump supplies oil to the day tank Figure 2 17 shows a flooded loop system The circulating pump is sized according to the maximum burner firing rate for all burners plus a 30 service factor The burner return lines feed into the common supply line INDUSTRIAL COMBUSTION RECOMMENDS THAT ALL OIL FIRING BURNERS BE EQUIPPED WITH AN OILSTRAINER 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 FILTRATION 14 OUTPUT TO BURNER SHUTOFF COCK SHUTOFF BURNER FROM SUPPLY SHUTOFF COCK 571 0012 FIGURE 2 6 OUTPUT TO BURNER SHUTOFF BURNER FROM SUPPLY SHUTOFF COCK 571 0013 Typical U L Gas Train Low High Off System Size 1 H10 to H25 FIGURE 2 7 15 OUTPUT TO BURNER BUTTERFLY SHUTOFF COCK REGULATOR SHUTOFF BURNER FROM SUPPLY 571 0014 Typical U L Gas Train Full Modulation System Size 1 H10 to H25 FIGURE 2 8 BUTTERFLY HIGH GAS c PRESSURE SWITCH OUTPUT TO BURNER LOW GAS PRESSURE SWITCH SHUTOFF COCK SHUTOFF BURNER FROM SUPPLY SHUTOFF COCK 571 0015 Typical U L Gas Train Low High Off Low High Low Size 2 H30 to H45 FIGURE 2 9 Full Modulation System Size 2 3 4 H30 to H125 16 NOZZLE PRESSURE TAP N C FAN HOUSING OIL VALVES BACK
72. so be made at regular intervals You access the coupling by removing the airbox cover and loosening the two setscrews on the flex 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 flow pattern exiting the nozzle A distorted flame 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 orifice A metal tool will distort the orifice 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 app
73. stion air flow 4 DIFFUSER An air flow diffuser stabilizes flame front OPERATION Air from the impeller flows through the blast tube and dif fuser to mix with fuel in the ignition zone Combustion air flow rate is determined by the position of the air regulating blades at the inlet of the impeller Linking the air flow with fuel flow provides efficient combustion at all firing rates F OIL SYSTEM Models HL HLGare high pressure atomizing burners using fuel pressure for atomization Atomized fuel is discharged from the nozzle as a fine conical spray 1 FUEL UNIT Direct driven from the blower motor with a flexible 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 flow delivering a speci fied amount at a specific pressure Fuel pressure mechani cal atomizes oil in a fine conical spray pattern from the nozzle orifice The burner is supplied with nozzle s to fire to its maximum rate unless a different firing rate was speci fied Return flow nozzle s are used on the full modulation 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 val
74. t at low fire with less than 50 ppm CO To obtain the proper readings adjust the air shutter and low fire regulator pressure 7 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water 8 Bring the burner to the high fire position and adjust the regulator pressure Adjust the high fire 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 fire is typically 2 to 4 O with less than 50 ppm CO The burner should be adjusted to provide correct fuel flow at a constant rate at the low fire and high fire position as indicated on the burner data plate This is achieved by clocking the gas flow 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 flow Gas Input HHV x Pgas x 520 x 3600 s x RATE ft Btu 29 92 Tgas 460 hr 5 hr Where HHV The higher heating value of the gas in Btu ft contact your local gas company for an exact measure ment Patm Atmospheric pressure in inches of mercury Pgas Gas pressure ahead of the volumetric flow meter in inches of mercury Tgas Gas temperature at the volumetric flow meter in Deg F RATE Natural gas rate taken with the volumetric flow meter in ft second
75. t burner into position for mounting and tighten into place All burners are equipped with a four hole mounting flange Refer to the general arrangement drawings in the Introduction section of the manual 5 Permanently support the burner using the pipe support connections 6 The space between the boiler refractory water leg or fire 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 13 E GAS PIPING Gas service and house piping must supply the guantity of gas demanded by the unit at the pressure reguired 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 butterfly valve are shipped loose These components should be mounted by the installer as close to the butterfly 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 6 through 2 9 for component arrangement Arrange gas piping at the burner so
76. t high fire to achieve rated heat input firing rate turndown optimum efficiency 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 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 fired units 5 Voltmeter Ammeter 6 Stack Thermometer and Thermocouples N WARNING READ THE FLAME SAFEGUARD MANUAL AND FULLY UNDERSTAND ITS CONTENT BEFORE ATTEMPT ING TO OPERATE THIS EQUIP MENT SERIOUS PERSONAL IN JURY OR DEATH MAY RESULT WARNING SHOULD A STARTING FAILURE OCCUR FOR ANY REASON COM BUSTIBLE FUMES MAY FILL THE COMBUSTION CHAMBER NEV ER ATTEMPT TO 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 firing and shutdown cycle The burner and control system are in starting condition when a The operating and high li
77. tarily 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 fire 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 firing oil flow and pres sure should be verified GAS BURNERS A representative of the gas utility should turn on the gas Determine by a test gauge upstream of the burner regulator that sufficient 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 Oninitial 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 finish 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 specificatio
78. that the burner is ac cessible 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 PIPING The HL and HLG model burners use pressure atomization Fuel oil is provided by a burner mounted fuel unit directly coupled to the blower motor via a flexible coupling The suction and return line sizes two pipe system are based on the suction rate of the fuel unit and not the burner firing 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 fittings strainers etc 3 The friction loss due to oil flow This loss varies with a Quantity of oil pum
79. to correct this situation For burners with the cam trim option adjust the cam screws throughout the range to obtain correct O and CO levels Continue to do this until the burner reaches high fire the potentio meter is at the OPEN position 10 Adjust the high fire gas input to match maximum rating At high fire the butterfly 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 fire is typically 2 to 4 O with less than 50 ppm CO as a target value Adjust the high fire excess air rate using the high fire shutter adjustment 11 Modulate the burner to low fire Verify the readings once again The burner should be adjusted to provide correct fuel flow at aconstant rate at the low fire and high fire position as indicated on the burner data plate This is achieved by clocking the gas flow 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 flow Gas Input HHV x Pgas x 520 x 3600 s x RATE Btu 29 92 Tgas 460 hr 5 hr Where HHV The higher heating value of the gas in Btu ft contact your local gas company for an exact measure ment Patm Atmospheric pressure in inches of mercury Pgas Gas pressure ahead of the volumetric flow meter i
80. until switch opens Interlock Operator Refer to instructions Manually adjust until switch opens Operator Check inspect and clean for soot buildup Operator Check for loosening of components erosion or carbon buildup ANNUALLY Strainer Oil units Replace or clean the oil strainer element Impeller 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 flame scanner or pilot Technician adjustment Operating Controls Service Refer to instructions Technician 36 High and Low Gas Pressure Interlocks Scanner and Diffuser Pilot Assembly SECTION 6 TROUBLE SHOOTING PROBLEM SOLUTION 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 reguires 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 fire limit switc
81. ut 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 23 Do not disturb established low fire adjustment Allow the burner to return to low fire 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 first using oil because as a fuel oil has a greater combustion air reguirement 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 flow of combustion air When conditions covered above are assured refer to letters F and G ofthis section NOTE COMBINATION GAS OIL UNITS USE ADIRECT COUPLING FROM THE BLOWER MOTOR TO THE OIL PUMP WHEN FIRING GAS FOR AN EXTENDED PERIOD OF TIME THE COU PLING 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
82. ves are part of the oil system on LO HI OFF and LO HI LO burners The two N C valves provide positive shut off of fuel oil while the one N O valve cycles the burner to high fire when closed 5 OIL METERING VALVE The firing rate is controlled by an adjustable metering valve in the return line At low fire the metering valve is open and is closed at high fire 6 OIL FILTER Prevents foreign matter from entering the burner oil system This item is provided optional and shipped loose with burner OPERATION Fuel oil is delivered to the fuel unit either by gravity fuel unit suction or by a circulating pump through a fuel oil filter Pressurized fuel returns to the storage tank until the two solenoid valves open On direct spark ignited burners HL 10 to 45 ignition occurs when the oil valves open Where gas pilots are provided Models HG and HLG the oil valves open after the pilot is proven Oil input rate is controlled by the oil metering valve which varies the flow to meet load demands The low fire positions bypass oil back to the storage tank At high fire the metering valve is in the closed position The modulating motor positions the metering valve and the air damper simultaneously G IGNITION SYSTEM Oil only models HL 10 to 45 are supplied with direct spark ignition Models HL 50 to 125 are supplied with a gas pilot system Gas and combination Gas Oil models are supplied with a gas ignition system The standard pilot

IC-SA-1248 H Series Manual 9-2009

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