V Manual

7/28/2019 V Manual

1/51

ONLY FACTORY AUTHORIZED BURNERSERVICE PERSONNEL SHOULD START- UP,

ADJ UST, OR SERVICE THIS EQUIPMENT.

WARNING

V/LNV SERIES

Installation,

Operation,

and

Service Manual

IC-1511

07/08

7/28/2019 V Manual

2/51

V SERIES TABLE OF CONTENTS

PAGESECTION 1. INTRODUCTIONA. GENERAL INFORMATION .............................................. 3B. DESCRIPTION................................................................. 3

C. OPERATING CONTROLS ............................................... 3D. FLAME SAFEGUARD CONTROLS................................. 3E. COMBUSTION AIR HANDLING SYSTEM....................... 4F. OIL SYSTEM ................................................................... 4G. PILOT SYSTEM ...............................................................4H. GAS SYSTEM.................................................................. 4

SECTION 2. INSTALLATIONA. DRAFT CONDITIONS ......................................................7

B. COMBUSTION AIR SUPPLY ........................................... 7C. COMBUSTION CHAMBER DESIGN ...............................7D. BURNER INSTALLATION ...............................................10E. GAS PIPING ................................................................... 11F. FUEL OIL PIPING ............................................................ 11G. INSTALLATION CHECKLIST...........................................16H. FIRING MODES...............................................................17

SECTION 3. STARTING AND OPERATINGA. PREPARATION FOR INITIAL START-UP ....................... 25B. FIRING PREPARATIONS ..............................................25C. SEQUENCE OF OPERATION ........................................26D. ELECTRICAL INTERFERENCE TEST ...........................26E. START-UP AND OPERATION ........................................27F. NORMAL OPERATION....................................................29G. SHUTDOWN....................................................................29

SECTION 4. ADJ USTMENTSA. GENERAL .......................................................................30B. COMBUSTION ADJ USTMENTS OIL AND GAS ............. 30C. GAS PILOT ADJ USTMENT ............................................ 31D. DIRECT SPARK OIL P ILOT ADJ USTMENT ...................31E. BURNER SETTINGS ...................................................... 31F. PILOT TURN DOWN TEST ............................................. 33

G. ON-OFF BURNER ADJUSTMENTS ...............................33H. LOW-HIGH BURNER ADJUSTMENTS ...........................34I. FULL MODULATION BURNER ADJ USTMENTS............ 36

PAGESECTION 5. MAINTENANCEA. GENERAL ........................................................................39B. CONTROL SYSTEM ........................................................ 39C. GAS SYSTEM.................................................................. 39D. OIL SYSTEM ...................................................................40E. DRAWER ASSEMBLY .....................................................40F. IGNITION ELECTRODE, CABLE, AND PILOT ...............40G. FLAME SCANNER ..........................................................40H. BURNER MOUNTING INSPECTION ..............................40

I. EXTENDED SHUTDOWN ................................................ 40J . MAINTENANCE FLOW CHART ...................................... 41

SECTION 6. TROUBLE SHOOTINGBURNER DOES NOT START ..............................................42NO IGNITION .......................................................................42PILOT BUT NO MAIN FLAME .............................................. 43BURNER STAYS IN LOW FIRE ...........................................43SHUTDOWN DURING FIRING.............................................44MODULATING MOTOR DOES NOT OPERATE ..................44

WARRANTY POLICY........................................................46-47

START-UP AND SERVICE REPORT ................................... 48

PRODUCT SATISFACTION SURVEY .................................49

7/28/2019 V Manual

3/51

1

OPERATING PRECAUTIONSThisoperating manual presents information that will help to properly operate and carefor the equipment. Study its contents carefully. The unit will provide good service andcontinued operation if proper operating and maintenance instructions are followed. Noattempt should be made to operate the unit until the principles of operation and all ofthe components are thoroughly understood. Only trained and authorized personnel

should be allowed to operate, adjust or repair this equipment.

If you are operating a burner(s), it is your responsibility to ensure that such operationis in full accordance with all applicable safety requirements and codes.

Placed on all Industrial Combustion burners are warning or caution labels designed toinform the operator of potential hazards and stress important information.

These symbols and their meanings are as follows:

HAZARD OF ELECTRIC SHOCK !!! MORETHAN ONE DISCONNECT MAY BE RE-QUIRED TO DISCONNECT ALL POWER

TO THIS PANEL. SERIOUS PERSONALINJ URY OR DEATH MAY RESULT.

READ PRODUCT MANUAL AND FULLYUNDERSTAND ITS CONTENTS BEFORE-ATTEMPTING TO OPERATE THIS EQUIP-MENT. SERIOUS PERSONAL INJ URY ORDEATH MAY RESULT.

TO AVOID PERSONAL INJ URY FROMMOVING PARTS, SHUT OFF ALL ELEC-TRICAL POWER BEFORE SERVICING

THIS EQUIPMENT.

WARNING

PROVIDE SUPPORT FOR THIS PANELTO PREVENT DAMAGE TO THE ELEC-TRICAL COMPONENTS.

CAUTION

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

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

CAUTION

WARNING

WARNING

WARNING

FAILURE TO INSTALL AND OPERATE THIS EQUIPMENT IN ACCORDANCE WITH THE

MANUFACTURERS RECOMMENDED INSTRUCTIONS AND INDUSTRY STANDARDS AND

PRACTICES CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE AND/OR PER-

SONAL INJURY !! READ THIS MANUAL IN ITS ENTIRIETY PRIOR TO ANY ATTEMPT TOCOMMISSION THIS EQUIPMENT. INSTALLATION, STARTUP, OPERATION AND MAINTE-NANCE OF THIS EQUIPMENT MUST BE PERFORMED ONLY BY FACTORY AUTHORIZED,EXPERIENCED AND QUALIFIED PERSONNEL.

7/28/2019 V Manual

4/51

2

Model designations are based on the type of fuel(s) tobe fired and the amount of furnace pressure to be over-come. Burner size is based on firing rate (rated input inBTU/HR).

EXAMPLE: Model number on nameplate isVLG-45, indicating it is a combination No. 2 oil and Gasburner with input rated at 4,500 MBTU per hour, againstfurnace pressures up to 2.0 W.C.

BURNER SIZE AND RATED FURNACE PRESSURE- V/BURNER:SIZE 1 - V13 to 34 1.0 W.C.SIZE 2 - V35 to 55 2.0 W.C.SIZE 3 - V60 to110 3.0 W.C.

SIZE 4 - V120 to 168 4.0 W.C.

THE INSTALLATION OF A BURNER SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF AUTHORITIES

HAVING JURISDICTION. THE EQUIPMENT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLELOCAL, STATE OR PROVINCIAL INSTALLATION REQUIREMENTS INCLUDING THE NATIONAL ELECTRICALCODE (NEC) AND ASSOCIATED INSURANCE UNDERWRITERS.

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

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

Further warning and caution references have beenmade in this manual and should be adhered to forsmooth operation of the burner.

WARNING

CAUTION

NOTE

This symbol precedes informationwhich, if disregarded, may resultin injury to the user of the burneror to others.

This symbol precedes information

which, if disregarded, may resultin damage to the burner.

This symbol precedes informationwhich is vital to the operation ormaintenance of the burner.

BURNER SIZE AND RATED FURNACE PRESSURE- LNV BURNER:SIZE 1 - LNV13 to 25 1.5 W.C.SIZE 2 - LNV30 to 50 2.5 W.C.SIZE 3 - LNV54 to 90 4.0 W.C.SIZE 4 - LNV100 to 147 4.5 W.C.

NOTE: Firing at higher furnace pressures de-ratesthe burner by appoximately 5% per one half inch ofadditional pressure. Consult with Factory.

RATED BURNER INPUT

SIZE MBTU/HR US GPH

13 1,300 9.3

15 1,500 10.7

17 1,700 12.1

20 2,000 14.3

21 2,100 15.025 2,500 17.9

30 3,000 21.4

34 3,400 24.3

35 3,500 25.0

40 4,000 28.6

42 4,200 30.0

45 4,500 32.1

50 5,000 35.7

54 5,400 38.6

55 5,500 39.360 6,000 42.9

63 6,300 45.0

70 7,000 50.0

80 8,000 57.1

84 8,400 60.0

90 9,000 64.3

100 10,000 71.4

105 10,500 75.0

110 11,000 78.6

120 12,000 85.7126 12,600 90.0

147 14,700 105.0

168 16,800 120.0

* Gas input based on natural Gas at 1,000Btu/cu.ft. and 0.60 specific gravity.

** Oil input based on 140,000 Btu/gal.

*** Refer to burner nameplate data for correctmanifold pressures.

MODEL FUEL ATOMIZATION

VG/LNVG GAS

VL #2 OIL PRESSURE

VLG/LNVLG #2 GAS/OIL PRESSURE

7/28/2019 V Manual

5/51

3

A. GENERAL INFORMATIONIndustrial Combustion V/Series burners are assembled,wired and tested at the factory. The V/series burner lineis listed by the Underwriters Laboratory for the U.S. and

Canada, and bears the UL and cUL markings when orderedas such by the customer. Compliance with other regula-tory agencies such as CSD-1, I.R.I./GE GAP, F.M., etc., isavailable at time or order.

Optional controls and control systems are also available.The operator of this equipment must be familiar with theindividual functioning of all controls to understand theoperations and procedures described in this manual, andsupplementary instructions provided with optional controls.Identify and locate each item in the illustrations as they aredescribed in the following sections.

B. DESCRIPTIONThe Industrial Combustion V/Series burners are designedto operate with gas and light oil. The burners are designedfor automatic, unattended operation except for periodic in-spection and maintenance. The control panel components

require little attention except for occasional cleaning.The burners are available in the following configuration

SIZE 1 -V13-34 - On-Off (Optional: Low-High-Off , Low-High-Low, Full Modulation)

SIZE 2 - V35-55 - Low-High-Off (Optional: Low-High-Low,Full Modulation)

SIZE 3 - V60-63 - Low-High-Off (Optional: Low-High-Low,Full Modulation)

SIZE 3 & 4 - V70-168 - Full Modulation

C. OPERATING CONTROLS - PANEL

The burner control panel my be integral to the burner orremote, and contains a flame safeguard programmingcontrol, motor relays (starters), and terminal strips mountedinternally on a panel subbase. Lights, switches, a controlcircuit breaker are mounted externally on the panel.

1. ON-OFF BURNER SWITCH

2. FUEL SELECTOR SWITCH - Gas - Off - OilGas position: Selects gas as the firing fuel

Off position: Burner offOil position: Selects oil as thefiring fuel

3. CONTROL CIRCUIT BREAKERSupplementary low overcurrent protection only.No larger than 15 amps.

4.AUTO-MANUAL MODULATION SELECTORSWITCH

Auto Position: Selects boiler modulation control. Inthis position, the burner will operate automatically inresponse to load demand.

Manual Position: Selects 135 ohm potentiometerfor manual modulating control.

5. MANUAL MODULATING CONTROL 135 ohm(For full modulation burners only) Increases ordecreases 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 isenergized (opened).

c. MAIN FUEL (green) illuminates when the mainfuel valve or valves are energized (open).

d. FLAME FAILURE (red) illuminates when the flame safeguard system fails to detect pilot or

main flame.

7. MODULATING MOTOROperates the air damper and fuel rate valves througha linkage system to adjust air-fuel ratios under all loadconditions.

8. IGNITION TRANSFORMERProvides high voltage spark for ignition of gas pilot ormain flame direct spark models.

D. FLAME SAFEGUARD CONTROLSTheflame safeguard controls the operating sequence of thecombustion system (prepurge, pilot, firing and shutdown)

The flame safeguard programmer incorporates a flamesensing cell (scanner) to shut down the burner in the evenof pilotflame or main flame failure. Other safety controlsshut down the burner based on sequence of operation asshown in the manufacturers flame safeguard manual.

ONLY FACTORY AUTHORIZED BURNERSERVICE PERSONNEL SHOULD START-UP,ADJ UST, OR SERVICE THIS EQUIPMENT

CAUTION

SECTION 1INTRODUCTION

7/28/2019 V Manual

6/51

4

When a parallel positioning system is furnished, theflamesafeguard may be incorporated as an integral componentto the parallel positioning control. Consult burner andcomponent technical documentation.

E. COMBUSTION AIR HANDLING SYSTEM1. MOTOR AND BLOWER -The impeller is directly drivenby the motor at 3450 rpm. A heavy-duty forward curved,multi-blade centrifugal impeller supplies combustion air.

2.AIR VOLUME REGULATOR - Air dampers are locatedin the air inlet housing. The dampers are mechanicallylinked and actuated by a two-position motor or hydrauliccylinder for on-off operation. Low-high-off, low-high-low orfull modulation burners have the dampers mechanicallylinked to the modulating motor.

3. COMBUSTION AIR PROVING SWITCH - A pressuresensitive, differential switch actuated by air pressure cre-ated by the blower fan. Contacts close to prove combustionair 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 airflow rate is determined by the position of the air regulatingblades at the inlet of the impeller. Linking the airflow withfuel flow provides efficient combustion at all firing rates.

F. OIL SYSTEMModels VL - VLG are high pressure atomizing burners usingfuel pressure for atomization. Atomized fuel is dischargedfrom the nozzle as a fine conical spray.

1. FUEL UNIT - Size 1 & 2 Direct driven from the blowermotor with aflexible coupling at 3450 rpm, and set for 300psi operation, fuel unit is two stage (two sets of gears) andmust be installed for a two pipe installation, one suction andone return line. Separately driven oil pumps are availableas option to the standard arrangement.Size 3 & 4 A separately driven oil pump is standard.

2. NOZZLE -The nozzle meters oilflow delivering a speci-fied amount at a specific pressure. Fuel pressure (mechani-cal) atomizes oil in a fine conical spray pattern from thenozzle orifice. The burner is supplied with nozzle(s) tofire toits maximum rate unless a differentfiring rate was specified.VL & VLG models 13-34 are supplied with simplex nozzles,models 35-168 are supplied with return flow nozzles.

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

4. OIL SOLENOID VALVES - Two normally closed (N.C.)and one normally open (N.O.) solenoid valves are part ofthe oil system on LO-HI-OFF and LO-HI-LO burners. The

two N.C. valves provide positive shut off of fuel oil while theone N.O. valve cycles the burner to HI fire when closed.

5. OIL METERING VALVE - Thefiring rate is controlled byan adjustable metering valve in the return line. At lowfire,the metering valve is open, and is closed at high fire.

6. OIL FILTER - Prevents foreign matter from enteringthe 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, fuelunit suction, or by a circulating pump, through a fuel oilfilter. Pressurized fuel returns to the storage tank until thetwo solenoid valves open. On direct spark ignited burners,(VL-13 to 55) ignition occurs when the oil valves open.Where gas pilots are provided (Models VG and VLG), theoil valves open after the pilot is proven. Oil input rate iscontrolled by the oil metering valve, which varies the flowto meet load demands. The low fire positions bypass oilback to the storage tank. At highfire, the metering valve is

in the closed position. The modulating motor positions themetering valve and the air damper simultaneously.

G. IGNITION SYSTEMOil only models VL-13 to 55 are supplied with direct sparkignition. Models VL-60 to 168 are supplied with a gas pilotsystem. Gas and combination Gas-Oil models are suppliedwith a gas ignition system. The standard pilot gas trainconsists of a manual shutoff cock, a gas pressure regulatorand a solenoid operated gas shutoff valve.

H. GAS HANDLING SYSTEMDepending upon the requirements of the regulating author-

ity, the gas control system and gas train may consist ofsome, 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 controlsthe rate offlow of gas.

2. MAIN GAS VALVES- Electrically operated safety shutoffvalve(s) that open to admit gas to the burner. StandardU.L. burners include:

-Models: 13-25; Diaphragm gas valve & solenoid valve-Models: 30-50; One motorized gas valve w/proof ofclosure or two safety shutoff valves.

-Models: 55-120; One motorized gas valve w/proof ofclosure and one safety shutoff valve.

-Models: 126-168; Two motorized gas valves(Two motorized gas valves can be optionally pro-vided on all models)

3.MAIN GAS REGULATOR -Regulates gas train pressureto specified pressure required at the burner manifold. Inputis set by main gas pressure regulator adjustment.

7/28/2019 V Manual

7/51

5

4. MAIN GAS COCKS - Used for manual shutoff of thegas supply upstream of the pressure regulator. A secondshutoff cock downstream of the main gas valve(s) providesa means of testing for leakage through the gas valve(s).

5. HIGH GAS PRESSURE SWITCH. (Models 30-168)A pressure actuated switch that remains closed when gaspressure is below a selected setting. Should the pressurerise above the setting, the switch contacts will open causing

main gas valve(s) to close. This switch requires manualreset after being tripped.

6. LOW GAS PRESSURE SWITCH. (Models 30-168)A pressure actuated switch that remains closed when gaspressure 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 requiresmanual 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 gasvalve modulates flow to burner input demand. The but-terfly valve is positioned through mechanical linkage bythe modulating motor. The air control damper is positionedsimultaneously by the modulating motor. The automaticgas valve(s) cannot be energized unless the combustionair proving switch is closed. The low and high gas pressureswitches must be closed to prove proper gas pressure.

GAS TRA IN COMPONENTS UP -S T R E A M O F T H E B U T T E R F L YVALVE ARE SHIPPED LOOSE TO

BE MOUNTED BY THE INSTALLER.

NOTE

PILOT GAS SUPPLY CONNECTION MUSTBE UPSTREAM OF THE MAIN GAS PRES-SURE REGULATOR

NOTE

Figure 1-1

656-00001

SCANNER

GAS PILOT TRAIN

ELECTRICAL ENCLOSURE

IGNITION TRANSFORMER

GAS BUTTERFLY VALVE

OIL METERING VALVE

AIRHOUSING

BLOWERMOTOR

MODULATING MOTOR

F.G.R. VALVE

OIL SOLENOID VALVE

A normally open vent valve, if required, is located betweenthe two automatic gas valves. This valve is shut whenthe automatic gas valves are open. When the automaticvalves are closed, the vent valve is open for venting gasto the outside, should any be present.

(Low NOx Only)

7/28/2019 V Manual

8/51

6

GAS MANIFOLD

DIFFUSER

AIR BAFFLE

MOUNTING FLANGE

CHOKE RING

NOZZLE BODY

AND TIP

RADIAL

GAS SPUDS

656-00002

Figure 1-2

Figure 1-3*Dimensions are in inches

S

A

G

J

CL

CL

CL

MODEL A B C D E F G H I J K L M N P R S T U

SIZE 1 32 7/8 12 3/8 4 8 1/4 3 3/4 15 9 3/4 30 9 3/4 7 3/8 12 7/8 11 1/4 6 1/2 14 3/8 13 12 5 /14 7 1/4 11 3/4

SIZE 2 37 1/3 13 5/8 4 10 4 18 1/8 8 34 1/2 10 1/2 7 3/8 15 13 1/4 7 1/2 15 1/8 12 1/2 12 3/4 6 1/4 9 14 1/2

SIZE 3 44 3/8 16 1/8 4 11 1/2 3 3/4 17 1/2 15 3/4 41 3/4 15 1/4 7 3/8 16 3/4 15 1/4 8 3/8 17 3/8 12 1/2 14 1/8 6 1/4 10 1/4 18 5/8

SIZE 4 54 3/8 24 7/8 5 13 5/8 4 25 1/4 12 45 7/8 13 1/2 7 3/8 17 1/2 15 3/8 8 3/4 20 1/8 14 1/2 16 7 1/2 12 1/4 19 1/4

BURNER STANDARD CONFIGURATION - REAR MOUNTED PANEL, GAS PILOT LINE PANEL MOUNTED

656-00037

C

B

H

E

F

I

D

K DIA.

M

N

PR

T

U

4X 3/4L B.C.

7/28/2019 V Manual

9/51

7

SECTION 2INSTALLATION

A. DRAFT CONDITIONSA boiler or other heating vesselfired with a V Series burner

does not depend on chimney draft for proper combustionair. Combustion air is supplied by the burner forced draftblower providing adequate air for any normal combustioncondition.

Since draft control is essential to maximum efficiency,a draft regulator may be required when the vessel is con-nected to a tall stack or where wind conditions may causeerratic draft. Excessive furnace draft contributes to inefficientburner operation.

Sealed boilers may be operated under positive fireboxpressure within the capability of the burner.

B. COMBUSTION AIR SUPPLYThe space in which a burner operates must be supplied

with adequate fresh air for combustion and ventilationpurposes. Fresh air supply must meet or exceed all coderequirements. Consult with insurance carrier and/or local

authorities for specific regulations.

C. COMBUSTION CHAMBER DESIGNIt 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 offive basic types:

1. Commercial Flex tubes watertube type boilers.2. Conventional Cast Iron sectional boilers.3. Conventional dry bottomfirebox 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.

5. Commercial Fire Tubes scotch marine type boilers.

WARNING

THE BOILER ROOM PRESSURE MUST BEAT LEAST EQUAL TO THE OUTDOOR ATMO-SPHERIC PRESSURE. WHERE FAN VENTILA-

TION IS USED, AIR MUST BE FORCED INTOTHE BOILER ROOM. NEVER EXHAUST AIRFROM THE BOILER ROOM. ADJOINING AREASHAVING EXHAUST FANS MUST BE POSITIVILYISOLATED FROM THE BOILER ROOM.

The V series burners are of the forced draftflame retention type. Refractory is required only to protect surfacesnot adequately protected by free circulating water. Foubasic objectives are:

1. Provide adequate combustion space.

2. Avoidflame impingement.3. Protect surfaces not adequately water cooled.4. Seal openings.

BURNER COMBUSTION CHAMBER

MODEL LENGTH WIDTH CL HEIGHT

13 56 26 12

15 56 26 12

17 56 26 12

20 56 26 12

21 56 26 12

25 56 26 1230 62 30 13.5

34 62 30 13.5

35 62 30 13.5

40 62 30 13.5

42 62 30 13.5

45 62 30 13.5

50 83 33 15

54 83 33 15

55 83 33 15

60 83 33 1563 83 33 15

70 83 33 15

80 104 39 18.5

84 104 39 18.5

90 104 39 18.5

100 128 39 18.5

105 128 39 18.5

110 128 39 18.5

120 128 39 18.5

126 128 39 18.5147 142 44 22

168 142 44 22

Suggested Minimum Combustion Chamber Dimensions inFigure 2-1 are based on the rated capacity of the burner

Figure 2-1

7/28/2019 V Manual

10/51

8

Firetube Boiler

CL

L

W

656-00006SUPPORT BURNER HERE

W

L

CL

656-00007

SUPPORT

BURNER

HERE

Cast Iron Boiler

FIGURE 2-2

FIGURE 2-3

While these dimensions are typical for good practice,satisfactory results may be achieved with modifications tosuit some conditions. Factors such as fuel properties, totalcombustion volume, length offlame travel often makefixedrequirements impractical. When in doubt, consult the fac-tory. Insulation should be provided between the refractoryand the boiler base. Mineral wool, or other material notlikely to settle is preferred. The chamber front wall may beconstructed offirebrick or insulating firebrick. Insulation

should be used between refractory and front plate. Fire-brick, or insulatingfirebrick should be set in high tempera-ture bonding mortar with provision for expansion.

GASKET MUST BE RESILIENT TO SEAL ANY UN-EVEN AREAS BETWEEN THE BURNER FLANGEAND THE BOILER FRONT PLATE TO PREVENTLEAKAGE OF COMBUSTION GASES.

CAUTION

7/28/2019 V Manual

11/51

9

Firebox Boiler

W

L

CH

656-00008

SUPPORT

BURNER

HERE

FIGURE 2-4

FIGURE 2-5Commercial Watertube

CH

L

SUPPORTBURNERHERE

7/28/2019 V Manual

12/51

10

D. BURNER INSTALLATIONPrepare the boiler front plate as follows:

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

2. Locate and scribe vertical centerline. Be sure stud loca-tions line up where studs will have full support. If they dontor if opening is too large, a steel adapter plate, 3/8 mini-

mum may be welded or bolted in place. Suitable anchorsshould be provided to hold refractory in place. Adapterplate must be properly sealed (use insulating rope gasket)to prevent leakage of combustion gases.

3. Using insulating rope gasket, wrap rope on the insideof the bolt circle, looping rope around the four mountingstuds.

4. Set burner into position for mounting and tighten intoplace. All burners are equipped with a four-hole mounting

flange. Refer to the general arrangement drawings inthe Introduction section o f the manual.

5. Permanently support the burner using the pipe supportconnections.

6. The space between the boiler refractory, water leg, orfire tube and outside diameter of the blast tube must bepacked 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.

FIGURE 2-6

7/28/2019 V Manual

13/51

11

E. GAS PIPINGGas service and house piping must supply the quantity

of gas demanded by the unit at the pressure required atthe burner gas train inlet.

All piping must be in strict accordance with applicablecodes, 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 areshipped loose. These components should be mounted bythe installer as close to the butterfly valve as practical.

Normally, the control train is ordered to suit a particularcode or insurance regulation - such as Underwriters Labo-ratories / Canadian Underwriters Laboratories (UL / cUL)Factory Mutual, or Industrial Risk Insurance. See Figure2-7 through 2-10 for component arrangement.Arrange gas piping at the burner so 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 connectedupstream of the main gas regulator. If a reducing bushingis 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 beperformed. (SEE SECTION 3-E)

F. FUEL OIL PIPING

PRESSURE ATOMIZATION OIL PIPING

The VL and VLG model burners use pressure atomization.Fuel oil is provided by a burner mounted fuel unit directlycoupled to the blower motor via aflexible coupling on Size1 & 2 Burners, Remote Pump on Size 3 & 4 Burners. Thesuction and return line sizes (two-pipe system) are basedon the suction rate of the fuel unit and not the burnerfiringrate. Pipe size must be selected so that suction vacuumis within suitable limits.

TWO PIPE - SINGLE BURNER OPERATION. A two-pipesystem is essential. The suction and return between the

storage tank or supply source and the burner must be sizedto supply the required quantity of oil circulated, includingexcess oil returned to the storage tank.

SUCTION LINE SIZING. The Suction load is determinedby:

1. The vertical lift from the oil level in the tank to thepump.

2. Pressure drop through valves, fittings, strainers, etc.

3. The friction loss due to oilflow. This loss varies with:a. Quantity of oil pumped (gph).b. Length of suction line (feet).c. Diameter of the suction line.d. Number offittings.

Although the gear type pumps used on the V series burnersare capable of developing higher suction, it is not desirableto operate above 15 inches of mercury vacuum. If the

vacuum is greater, flow may be erratic.

Refer to the manufacturers table for li ne sizing

1. Check suction capacity.

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

3. Read up from line total feet of copper tube to theintersection line of the specific suction capacity ing.p.h.

4. Read left to column inches of vacuum at fuel unit

This is vacuum required to draw oil through pipe listed agiven 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 shouldbe sized the same as the suction line.

TWO PIPE - MULTIPLE BURNER SYSTEM. Severaoptions exist for a multiple burner installation. In Figure

2-16 a typical installation showing separate suction linesfor each burner with a common return line.Figure 2-17 shows multiple burners with oil supplied by atransfer pump. The circulating pump is sized, in this casefor the total suction capacity of all burners. Note that aspecial pressure regulating valve is required if the fuel uniinlet pressure is above 3 psi.Figure 2-18 shows an installation using a day tank. A pumpsupplies oil to the day tank.Figure 2-19 shows a flooded loop system. The circulatingpump is sized according to the maximum burnerfiring ratefor all burners plus a 30% service factor. The burner returnlines feed into the common supply line.

NOTEINDUSTRIAL COMBUSTION RECOMMENDS THATALL OIL FIRING BURNERS BE EQUIPPED WITH ANOIL STRAINER (IF NOT INCLUDED WITH THE BURN-ER) TO PREVENT PARTICLES FROM CLOGGING

THE NOZZLE. IT IS ESSENTIAL TO FOLLOW THESTRAINER MANUFACTURERS MAINTENANCESCHEDULE TO ENSURE PROPER FILTRATION.

7/28/2019 V Manual

14/51

12

Typical U.L. Gas Train - On-Off System - Size 1 V13 to V34

Typical U.L. Gas Train - Low-High-Off System - Size 1 V13 to V34

FIGURE 2-7

FIGURE 2-8

571-0013

INPUT

FROM SUPPLY

PILOT

REGULATOR

TO

BURNER

PILOT

VALVE

PILOT

SHUTOFF

COCK

SHUTOFF

COCK

MAIN

GAS

VALVE

MAIN

GAS

VALVE

REGULATOR

SHUTOFF

COCK

OUTPUT

TO BURNER

A

A

571-0012

INPUT

FROM SUPPLY

PILOT

REGULATOR

TO

BURNER

PILOT

VALVE

PILOT

SHUTOFF

COCK

SHUTOFF

COCK

MAIN

GAS

VALVE

MAIN

GAS

VALVE

REGULATOR

SHUTOFF

COCK

OUTPUT

TO BURNER

A

A

7/28/2019 V Manual

15/51

13

Typical U.L. Gas Train - Full Modulation System - Size 1 V13 to V34

Typical U.L. Gas Train - Low-High-Off, Low-High-Low, Size 2 V35 to V63Full Modulation System - Size 2-3-4 V35 to V168

571-0015

HIGH GAS

PRESSURE

SWITCH

LOW GAS

PRESSURE

SWITCH

A

A

A

BUTTERFLY

VALVE

SHUTOFF

COCK

MAIN

GAS

VALVE

MAIN

GAS

VALVE

OUTPUT

TO BURNER

INPUT

FROM SUPPLY

SHUTOFF

COCK

PILOT

REGULATOR

TO

BURNER

PILOT

VALVE

PILOT

SHUTOFF

COCK

A

REGULATOR

FIGURE 2-9

FIGURE 2-10

571-0014

BUTTERFLY

VALVE

SHUTOFF

COCK

MAIN

GAS

VALVE

MAIN

GAS

VALVE

OUTPUT

TO BURNER

INPUT

FROM SUPP LY

SHUTOFF

COCK

PILOT

REGULATOR

TO

BURNER

PILOT

VALVE

PILOT

SHUTOFF

COCK

A

REGULATOR

A

7/28/2019 V Manual

16/51

14

On-Off Oil System Size 1 - V13 to V34Low-High-Off, Low-High-Low Oil SystemSize 2 - V35 to V55

Full Modulation Oil System Size 1 - V13 to V34Simplex Nozzle

Full Modulation Oil System Size 2- V35 to V55Return Flow Nozzle

FIGURE 2-12

FIGURE 2-14

FIGURE 2-11

FIGURE 2-15

N.C.OIL VALVES OIL

NOZZLE

FUEL UNITPRESSURE TAP

OILSUPPLY

OIL RETURNTO TANK

FUEL UNIT

656-00011

OIL NOZZLEPRESSURE TAP

OIL

NOZZLE

N.C.

OIL VALVES

656-00012

OIL

SUPPLY

OIL RETURN

TO TANK

FUEL UNIT

FUEL UNIT

PRESSURE TAP

MODULATING

MOTOR

OIL NOZZLE

PRESSURE TAP

OIL

PRESSURE

SWITCH

N.C.

OIL VLAVES

MODULATING

MOTOR

OIL RETURN

TO TANK

OIL

METERING

VALVE

OIL NOZZLE

PRESSURE TAP

FUEL UNIT

PRESSURE TAP

CHECK VALVE

OIL

NOZZLE

OILSUPPLY

656-00014

656-00013

N.C.

OIL VALVES

OIL NOZZLE

PRESSURE TAP

OIL

NOZZLE

MODULATING

MOTOR

OIL RETURN

TO TANK

OIL

SUPPLY

OIL

METERING

VALVE

FUEL UNIT

FUEL UNIT

PRESSURE TAP

FUEL UNIT

PRESSURE TAP

CHECK VALVE

OIL NOZZLEPRESSURE TAP

N.C.OIL VALVES

OILNOZZLE

OIL SUPPLY

OIL RETURNTO TANK

OIL

METERINGVALVE

FUEL UNIT

PRESSURE TAP

FUEL UNIT

FUEL UNITPRESSURE TAP

MODULATINGMOTOR

656-00029

Remote Pump System

FIGURE 2-13

7/28/2019 V Manual

17/51

15

571-0016

OIL

METERING

VALVEFUEL

UNIT

OIL

METERING

VALVEFUEL

UNIT FILTER

GATE

VALVE

GATE

VALVE

GATE

VALVE

CHECK

VALVE

CHECK

VALVE

CHECK

VALVE

BURNER

NOZZLE

CHECK

VALVE

FILTER

OIL RETURN

OIL INLET

BURNER

NOZZLE

OIL INLET

OIL RETURN

GATE

VALVE

SUPPLY

TO BURNERS

RETURN TO TANK

OIL

SUPPLY

TANK

Multiple Burners with separate suction lines

Typical Oil Loop for Multiple Burners with Transfer Pump

Typical Installation Using Day Tank

FIGURE 2-16

FIGURE 2-17

FIGURE 2-18

571-0017

CHECK

VALVE

VOLUME

CONTROL

BY-PASS

CHECK

VALVE

GATEVALVE

PRESSURE

GAUGES

W/ISOLATORS

PRESSURE GAUGE

W/ISOLATOR

BACK PRESSURE VALVESET BELOW 3 PSI

RELIEF

VALVE

TRANSFER

PUMP

VACUUM OR COMPOUNDGAUGE W/ISOLATOR

CHECKVALVE

GATEVALVE

GATEVALVE

STRAINER

OILMETERING

VALVEFUELUNIT

OILMETERINGVALVEFUEL

UNIT FILTER

GATEVALVE

CHECKVALVE

BURNERNOZZLE

CHECKVALVE

FILTER

OIL RETURN

OIL INLET

BURNERNOZZLE

OIL INLET

OIL RETURN

GATEVALVE

SUPPLY TO BURNERS

RETURN TO TANK

OILSUPPLYTANK

571-0018

GATE

VALVE

CHECK

VALVE

STRAINER

DAY

TANK

RELIEF

VALVE

TRANSFER

PUMP

VACUUM OR COMPOUND

GAUGE W/ISOLATOR

CHECK

VALVE

GATE

VALVE

GATE

VALVE

STRAINER

OIL

METERING

VALVEFUEL

UNIT

OIL RETURN

OIL INLET

BURNER

NOZZLE

OIL

SUPPLY

TANK

7/28/2019 V Manual

18/51

16

G. INSTALLATION CHECKLIST1. All burners are carefully assembled and tested at thefactory, but before being placed in service all connectorsshould again be checked for looseness caused duringshipment.

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 pumpsor fuel unit without 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 rotatingin the proper direction.

5. Before firing, make sure the burner firing head anddry areas of the boiler are protected with refractory. Theburner mountingflange must be properly sealed against

the vessel front plate.

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

Typical Flooded Loop System

CAUTIONBEFORE OPENING THE MANUAL GASSHUT-OFF VALVES, READ THE REGULA-

TOR INS TRUCTIONS CAREFULLY. THEINSTRUCTIONS ARE IN THE REGULATORBOX. FOLLOW THE MANUFACTURER REC-OMMENDATIONS. OPEN SHUT-OFF VALVEON THE INLET SIDE OF THE REGULATORSLOWLY AND CAREFULLY TO ALLOW IN-LET PRESSURE TO BUILDUP SLOWLY IN

THE REGULATOR UNTIL IT IS FULLY PRES-SURIZED. OPENING THE SHUT-OFF VALVEQUICKLY WILL DAMAGE THE REGULATOR.D O NO T E X C E E D T HE R E G U -L A T O R P R E S S U R E R A T I N G S .

FIGURE 2-19

571-0019 DUPLEX PUMP SYSTEM

6"MINIMUM

VACUUM BREAKER

STRAINERGATEVALVE

VACUUM GAUGEW/ISOLATOR

GATEVALVE

TRANSFERPUMP

GATEVALVE

TRANSFERPUMP

STRAINER

GATEVALVE

VACUUM GAUGEW/ISOLATOR

CHECKVALVE

OILSUPPLYTANK

PRESSUREGAUGE

GATEVALVE

CHECKVALVE

STRAINER


UNIT

OIL RETURN

OIL INLET

BURNERNOZZLE

PRESSUREGAUGE

GATEVALVE

CHECKVALVE

STRAINER


UNIT

OIL RETURN

OIL INLET

BURNERNOZZLE

7/28/2019 V Manual

19/51

17

CombustionAir

Gas

Oil

ON-OFFOPERATION

COMPONENTS

DESCRIPTION:

Fixedtwobladeddamper.

PRE-PURGE:

Valvesareclosed.

Thevalvesareclosed.

Theoilpump

isoperatingwithpre-purge,

butoilisflowingthroughaninternalreliefandreturningtothe

supplysystem.

STARTUP,

IGNITION:

Valvesopen.

Topreventasurgeofgasfromreachingthe

manifold,

theprimarygasvalvesopenataslowedra

te.

Thevalvesopenallowingpressurize

doiltoflowfrom

thepump

tothenozzle.

RUN,

MODULATE:

Valvesremainopen.

Valvesremainopen.

SHUTDOWN,

POST-PURGE:

Onshutdownallgasvalvesclosewithin1second.

Valvescloseimmediately.

Theoilpumpisoperatingwithpost-

purge,

butoilisonceagainrelievedtothesupplysystem.

VARIATIONS:

None

None

None

PressureAtomization:Twosolenoidtypesafetyshutoffoil

valvesinitiatetheflowofoilfromthe

highpressurepumptothe

nozzle.

Oilflowrateisfixedbasedon

pumpoilpressureandthe

simplexnozzle'sflowrating.

Twosafetyshutofvalvesareprovidedtoinitiatethe

flowofgas.

The

primary

is

a

diaphragm

ormotorized

type

valve.

On

diaphragm

gasvalvethetimetoopencanbead

justedbya

bleedvalve.

Onmodelswithmotorizedvalvesthetimetoopen

isfixedat13seconds.

Amanuallyadjustedgasreg

ulatorlimits

firingrate.

OPERATION

The

damper

provided

on

a

on-offis

adjusted

at

the

time

the

burner

is

installedand

fixedinplace.

Theopen

damperpositionallowsafixedrateofai

flow

during

all

aspects

of

burne

operation

wh

ile

the

blowermotoris

operational.

H. FIRING MODES

7/28/2019 V Manual

20/51

7/28/2019 V Manual

21/51

7/28/2019 V Manual

22/51

7/28/2019 V Manual

23/51

7/28/2019 V Manual

24/51

7/28/2019 V Manual

25/51

7/28/2019 V Manual

26/51

7/28/2019 V Manual

27/51

25

SECTION 3STARTING UP AND OPERATION

A. PREPARATION FOR INITIAL START-UPWhen the installation is complete and all electrical, fuel,

water and vent stack connections are made, make certainsaid connections are tight. The operator should becomefamiliar with the burner, boiler controls and components.

To identify controls and components refer to drawings and

contents of Section 1. Adjustment procedures given in Sec-tion 4 should be reviewed prior tofiring. The wiring diagramshould also be studied along with the operating sequenceof burner programmer. Check the electrical power supplyfor accordance with the nameplate specifications for allmotors and controls.

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

BOILER.

Check boiler water level. Be sure all boiler valves areinstalled correctly and positioned properly. Set the high limitcontrol slightly above the operating control. Set operatingcontrol at the desired temperature or pressure.

BURNER.

For protection in shipment, theflame safeguard controlchassis 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 witha screw which, when tightened, completes the connectionbetween 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 compliancewith the wiring diagram and local codes. The control cabinetcomponents are 120 volt. If a control transformer is sup-plied, ensure that the supply voltage matches its primaryvoltage.

Check motor rotation by momentarily closing the starteror relay. Blower rotation is clockwise when viewed from thedrive end.

Check the pilot electrode setting. Refer to the ADJ UST-MENT section.

Check control linkage for proper movement of the airvolume damper and fuel metering components. This canbe done by loosening the linkage at the actuator lever andmanipulating by hand.

Check the air shutter and adjust low fire setting. Referto the ADJ USTMENT section.

B. FIRING PREPARATIONSCheck to make certain that all plugs, connections, link

ages etc., are tight. Prior to initialfiring, oil flow and pressure should be verified.

GAS BURNERS

A representative of the gas utility should turn on the gasDetermine by a test gauge upstream of the burner regulatothat sufficient pressure exists at the entrance to the gastrain. The gas pressure regulator must be adjusted to thepressure required and the pressure setting recorded.

On combination fuel models, set the selector switch togas. On initial start-up it is recommended that the main gasshutoff cock remain closed until the programmer has cycledthrough pre-purge and pilot sequences to determine thathe main gas valve opens. Turn the burner switch OFFand let programmerfinish its cycle. Check to see that gasvalve closes tightly.

On burners equipped with high and low gas pressureswitches, set switch pressure actuating levels and recordsettings for future service reference.

See the burner specification nameplate inside the control panel door for minimum and maximum input rate andrequired manifold pressure.

When the conditions covered above and in Section 2 areassured, the burner is ready for firing. Refer to Section Efor starting and operating information.

OIL BURNERSPrior to initialfiring, oilflow and pressure should be verified. If the burner is a dual fuel model, make certain thathe main gas shut off cock is closed and the fuel selectoswitch 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 prioto starting the pump to avoid possibility of damage to pumpthrough operation without lubrication.

To check for proper pump rotation, momentarily energizethe starter. With rotation verified, operate the pump to de

termine that oil circulation exists. Observe the oil burnepressure gauge. If no pressure shows after a few momentsstop the oil pump and re-prime. If the supply tank is lowethan the pump, it is possible that the initial priming of thesuction line, followed by operation of the pump, will noestablish oil flow. This might be caused by obstruction inthe suction line, excessive lift, inadequate priming, suctionline leaks, etc. Until oilflow is established, avoid prolongedoperation of the pump. If oil flow is not established after asecond priming, investigation is required.

7/28/2019 V Manual

28/51

26

A vacuum (or compound pressure-vacuum) gaugeshould be installed at the suction port of the pump. It isadvisable 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 coppertubing, 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, eitherfrom a gravity or by pump circulation, the pressure must notexceed 3 psi at the fuel unit suction inlet. Special pressureregulating valves are available for suction pressure above3 psi. The fuel unit discharge pressure should be set at300 psi.

BURNER SETTINGS

To ensure reliable and safe burner performance, thelocation and gap setting of the electrode for direct-sparkigniters, 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 theestablishedflow rates, to provide the correct amount of airfor complete efficient combustion.

These items are preset at the factory, but must bechecked prior to placing the burner into initial service, orafter conducting any service work that may have alteredtheir position.

Refer to Section 4, ADJ USTMENTS, for the instruc-tions.

COMBUSTION SETTINGS

Fuel and air flow rates are individually adjusted at lowfire and at high fire to achieve rated heat input, firingrate turndown, optimum efficiency, safe operation, andthe ability to cope with environmental changes (includingair temperature, humidity, barometric pressure), and fuelproperty changes. Refer to the nameplate inside the controlpanel for minimum and maximum fuel input ratings.

Refer to Section 4, ADJ USTMENTS, 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 gaspressures (Main and Pilot), pressure and vacuum gaugefor the oil burners.3. Inclined manometer to measure draft pressures.4. Smoke spot tester for oil burners and CO analyzer forgasfired units.5. Voltmeter / Ammeter6. Stack Thermometer and Thermocouples.

WARNING

READ THE FLAME SAFEGUARDMANUAL AND FULLY UNDERSTANDITS CONTENT BEFORE ATTEMPT-ING TO OPERATE THIS EQUIP-MENT.. SERIOUS PERSONAL IN-

J URY OR DEATH MAY RE SULT.

WARNINGSHOULD A STARTING FAILUREOCCUR FOR ANY REASON, COM-BUSTIBLE FUMES MAY FILL THECOMBUSTION CHAMBER. NEV-ER ATTEMPT TO RE-LIGHT THEBURNER UNDER THESE CONDI-

TIONS WITHOUT FIRST PURGING

C. SEQUENCE OF OPERATIONThe programming control sequences the operation of

all controls and components through the starting, ignition,firing, and shutdown cycle. The burner and control systemare in starting condition when: a. The operating and highlimit control (temperature or pressure) are below their cutoffsetting; b. All power supply switches are closed; c. Poweris present at the control panel.

Refer to the manufacturers literature on programmingcontrols and burner wiring diagrams for detailed informa-tion.

D. ELECTRICAL INTERFERENCE TESTPrior to putting the burner into service, conduct the fol-

lowing test to ascertain that ignition spark will not causethe flame relay to pull in.

GAS FIRED

Close the pilot and main line manual gas valves. Startthe burner and at time of pilot trial with just the electricalignition system energized. The flame relay should not pullin (i.e. should not be energized).

Upon completion of successful test, proceed with start-upprocedures.

OIL FIREDDisconnect the electrical power to the burner. Discon-

nect the electric oil safety shutoff valve. Reconnect electricpower. Close the pilot line manual gas valve, if used.

Start burner and at the time of pilot trial, with just theelectrical ignition system energized. Theflame relay shouldnot pull in.

Upon completion of successful test, disconnect powersupply. Reconnect oil safety shutoff valve and turn onmanual pilot gas valve. Reconnect power supply andproceed with start-up procedures.

7/28/2019 V Manual

29/51

27

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 theautomatic safety shutoff valves located in the main gastrain prior to any initial commissioning or subsequentmaintenance of the burner and gas train systems where

automatic valve proving systems interlocked with the mainburner safety control are not provided. This test shouldbe performed periodically to ensure no leakage of valvesin their closed or de-energized position.

Refer to the diagram below when following thisprocedure. The unit should be taken out of service if theunit fails any of the following tests. Any defective partmust be replaced prior to putting the equipment back intoservice.

Close (or shut off) manual valve [7] downstreamof the automatic safety shutoff valves, trappinggas pressure between the safety shutoff valvesand manual valve and causing a flame failure.

This should close the auxiliary safety shutoffvalve [4] and main gas safety shutoff valve [5]. Ifboth 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 safetyshutoff valve [5], then conduct a bubble test forleak through blocking valve [5]. If no leak, close

the test cock.

Release gas pressure at test cock [8A] andbubble test for leak through auxiliary safetyshutoff valve [4]. If you do not observe a leak,close test cock and go to next step. If eithervalve leaks, correct the problem and retest 10

times before proceeding.

When there are no valve leaks, open manualvalve [7] and relight the burners. Then closemanual 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 itreaches the operating gas pressure, whichshould cause the auxiliary and main gas safetyshutoff valves to close from high gas pressure.Return the setpoint to its original position before

proceeding.

Shut off the combustion air blower. This shouldcause a failure due to low air pressure and

cause the safety valves to close.

Reset all manual valves to their normal settingfor operation. Make sure all electric valves areoperating normally. Make sure all test cocks areclosed before resuming normal operation.

WARNING

FAILURE TO FOLLOW THIS PROCEDURE MAYRESULT IN EXPLOSION, FIRE, PROPERTYDAMAGE AND PERSONAL INJURY. THIS PRO-CEDURE MUST BE PERFORMED ONLY BYAUTHORIZED AND QUALIFED PERSONNEL.

7/28/2019 V Manual

30/51

28

Close the downstream main and pilot gas cocks. Makesure the ON-OFF switch is in the OFF position. Actuatethe manual reset button of the flame safeguard control toclose the safety switch contacts.

For LOW-HIGH-OFF or LOW-HIGH-LOW and FULLMODULATION models set the MANUAL-AUTO switchto the MANUAL position.

Set the manual potentiometer to lowfire position.

Open the gas pilot cock. check pressure. Normal settingis 4 to 6 WC when the pilot is burning.

Set the ON-OFF switch to ON. The burner will startand pre-purge. After pre-purge, the ignition transformerand the gas pilot solenoid are energized.

On initial start-up it is recommended that the main gasshutoff cock remain closed until the programmer has cycledthrough prepurge and pilot sequence. Then determine thatmain gas valve opens. When this is confirmed, turn theburner 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 andallow programmer to recycle for a new ignition trial.

Turn burner ON and after pilot ignition when the flamerelay pulls in, the slow opening, motorized, main gas valveis energized. Slowly open the downstream manual shutoffgas cock. Mainflame should ignite at this time. The gasvalve and air damper continue advancing until highfire isreached.

Do not repeat unsuccessful light off attempts withoutrechecking burner and pilot adjustment. Vent fuel vapors

from the combustion chamber after each unsuccessful lightoff attempt. Set the gas lowfire rate by adjusting butterflyvalve and air linkage. Refer to the adjustment section ofthis manual. Using combustion analysis instrument adjustthe lowfire. Typical combustion analysis for lowfire is 5 to6% O2 on standard turndown systems, and between 6.5%and 9% for higher turndown systems. Verify the minimuminput rate by measuring the gas meter.

When lowfire is adjusted, shut down burner. Restart sever-al times to be sure the lowfire setting is suitable. Readjustif necessary. Never start the burner with fuel vapor in thefurnace. In case of emergency, open main power switchesand close all fuel valves. After combustion adjustments aresatisfactorily set, allow the heating vessel to slowly reachnormal operating pressure or temperature.

After the boiler has reached operating temperature or pres-sure, turn the potentiometer switch in small increments tothe high fire position. Check high fire at this point usingcombustion instruments. High fire combustion analysistypically is 3.0 to 4.0 percent O2. Verify maximum inputrate by measuring the gas meter.

Do not disturb established lowfire adjustment. Allow theburner to return to lowfire position before adjusting high orintermediate settings. CO levels should be less than 400ppm on an air-free basis at all firing rates, with

7/28/2019 V Manual

31/51

29

Do not disturb established low fire adjustment. Allow theburner to return to low fire position before adjusting highor intermediate settings.

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

COMBINATION GAS-OIL BURNERS In general, the combination fueled system is to bestartedfirst using oil, because, as a fuel, oil has a greatercombustion air requirement than natural gas.

Refer to the Gas burner or Oil burner adjustmentprocedures and to Section 4, ADJ USTMENTS.

Once the adjustments are set for oil, shut-down theburner and re-start and adjust the natural gas fuel. DONOT READJ UST THE AIR DAMPERS. The adjustment ismade by balancing the fuel input rate against the existingflow of combustion air.

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

F. NORMAL OPERATIONNormal operation must be with the MANUAL-AUTO

switch selector at AUTO.

In automatic operation, the operating cycle always proceeds sequentially through pre-purge, pilot ignition, mainflame ignition, run and post-purge. The length of purgeand ignition trial vary according to the type of programmeused.

During the run cycle, burner input is regulated to the loaddemand by the modulating pressure or temperature controon the boiler. The burner will continue to modulate untthe operating pressure or temperature is reached.

Programmer control operation should be tested whenthe burner is initially placed into service, when a control isreplaced, and at scheduled intervals in the maintenanceprogram.

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

G. SHUTDOWN

When the operating limit control setting is reached othe burner switch is turned OFF, the following sequenceoccurs:

The fuel valve(s) de-energize and flame extinguishesThe blower motor continues running during post-purge (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 positionand stops. Unit is ready to restart.

Abnormal shutdown might result from motor overload

flame outage, low water, current or fuel supply interruptioncombustion or atomizing air pressure below minimum leveltripped circuit breakers, blown fuses, or other interlockdevices. Check for cause and correct before restartingburner.

Safety shutdown caused by ignition orflame failure wilactuate a red indicator light and energize an audible alarm(if so equipped). If the programmer has a non-recyclinginterlock circuit, any interruption in this circuit during thepre-purge orfiring cycle will cause a safety shutdown. Thistype of shutdown requires manual reset of the programming control and must be corrected before operation canbe resumed.

SIZE 1 & 2 COMBINATION GAS/OIL UNITSUSE A DIRECT COUPLING FROM THEBLOWER MOTOR TO THE OIL PUMP. WHENFIRING GAS FOR AN EXTENDED PERIODOF TIME, THE COUPLING SHOULD BEMANUALLY REMOVED AND REPLACEDONLY WHEN FIRING OIL. IF THE COUPLINGIS LEFT CONNECTED TO THE BLOWERMOTOR, ENSURE THAT THERE IS PROPEROIL CIRCULATION AT ALL TIMES TO AVOIDDAMAGE AND SEIZURE OF THE PUMP.

NOTE

BLOWER

MOTOR

IMPELLERWHEEL

FLEXIBLE

COUPLING

ACCESSCOVER

656-00015

Figure 3-1

7/28/2019 V Manual

32/51

30

SECTION 4ADJUSTMENTS

A. GENERALWhile each burner is tested at the factory for correct

operation before shipment, variable conditions such asburning characteristics of the fuel used and operating loadconditions may require 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, connectingpiping, wiring, and all fastenings such as nuts, bolts andsetscrews to be sure that no damage or misadjustmentsoccurred during shipment and installation.

A combustion efficiency analysis made during the initialstart-up will help to determine what additional adjustmentsare required in a particular installation.

B. COMBUSTION ADJUSTMENT ON OILAND GAS

Efficient combustion cannot be properly judged byflame

appearance, although it may help in making preliminarysettings.

The proper settings of air-fuel ratios must be determinedby flue gas analysis. Combustion gas analysis indicatesthe air to fuel ratio and the degree of complete combus-tion. Instruments are available to measure carbon dioxide(CO2), oxygen (02), and carbon monoxide (CO). At notime should CO2 measurements alone be used to indi-cate proper excess air levels. Only O2 measurement candefinitively show whether sufficient air has been providedfor combustion.

STACK TEMPERATURE

Net stack temperature is obtained by subtracting theambient temperature from theflue gas temperature. A highnet stack temperature indicates wasted heat. Decreasingeither the temperature or the volume of the flue gas, orboth can reduce stack heat loss. Flue gas temperature isreduced by improving heat transfer or by reducing excesscombustion air. A certain amount of excess air is necessaryto 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 somewhataccording 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-airratio, excessive air leaks in the combustion chamber, orimproper fuel oil temperature.

TEST EQUIPMENT

The following test equipment should be used to set-upand adjust the burner correctly:

1. 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 / Ammeter6. Stack Thermometer and Thermocouples.

AIR FLOW ADJUSTMENTS

The V/Series burners have a two blade air shutterdesign. Both blades are coupled together, and attachedto the modulation motor. Changing the positions of thelinkage rods on the linkage control arms will change theway the damper blades open and close.

COMBUSTION SETTINGSFuel and air flow rates are individually adjusted at low-

fire and at high-fire to achieve rated input, firing rateturndown, optimum efficiency, safe operation, and theability to cope with environmental changes (including airtemperature, humidity, barometric pressure), and fuelproperty changes.Turndown capability for oil is less than that for gas due

to the excess air requirement of oil for clean combustion.Therefore, on combination fueled burners, gas turndownperformance may be restricted (or determined) by theexcess air levels set initially for oil combustion. For burnersequipped with the optional Siemens modulating motor,gas turndown will not be limited to the oil setting. Eachfuel will have a separate modulation range, independentof each other.Two key components residing influe gas are used tooptimize combustion efficiency; excess air and unburnedfuel. The system should be adjusted to the minimumexcess air quantity that provides low levels of unburnedfuel with sufficient remaining oxygen to cope with normalatmospheric and fuel related changes. Unburned fuelis measured as carbon monoxide (CO) when burningnatural gas, and smoke spots when burning oil.

GAS ADJUSTMENTSLowfire combustion analysis typically is 6 to 9 percent O2and less than .04 percent CO (400 ppm). Highfire readingtypically is 3 to 5 percent O2 and less than .04 percent CO.

The V/Series burners are capable of operating at low excessair and less than 50 ppm CO levels at all firing rates.

FUEL OIL ADJUSTMENTS

Adjust for a clean fire. Typically for No. 2 oil, O2 is 5to 6 percent at lowfire and 3.5 to 4.5 percent at high fire.

The burner should be set-up and maintained to yield

7/28/2019 V Manual

33/51

31

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 VG-VLG and VL-60 to 168 are equippedwith a gas pilot system. The gas pilotflame is regulated byadjusting the pressure setting of the pilot regulator. Normalsetting is 4 to 6 WC when the pilot is burning. The flamemust be sufficient to be proven by the flame detector and

ignite the mainflame. Although it is possible to visibly ad-just the size of the pilotflame, obtain a proper DC volt or

microamp reading of the flame signal.The flame safeguard amplifier has a meter jack for this

purpose. At initial start-up and during planned maintenance,test the pilotflame signal, pilot turndown, and safety switchlockout. Refer to theflame safeguard instruction manual.

Check the pilot electrode setting. The pilot is accessibleby loosening the four screws on the side of the blast tubeand disconnecting the gas line.

D. DIRECT SPARK OIL PILOT ADJUSTMENT Burner models VL-13 to 55 are equipped with a directspark ignition. Remove the oil drawer assembly and checkelectrode settings and nozzle size.

E. BURNER SETTINGSTo 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 bafflecomponents must be set correctly. These items are presetat the factory, but must be checked prior to placing theburner into initial service, or after conducting any servicework that may have altered their position.

The nozzle/diffuser assembly must be removedfrom inside the burner to enable measurement andadjustment.Remove as follow:1. Lock out and tag the electrical power supply to theburner to prevent inadvertent operation during check-out or maintenance activities.2. Disconnect the high voltage power supply from the oil-spark-ignition electrodes (if installed).3. Disconnect the oil piping from the side of the blast tube.4. Remove the fasteners that secure the drawer to theside of the burner housing, and remove the completeassembly.5. For burners with a gas pilot: Disconnect the pilot line

and loosen the locking screws on the pilot accesscover located on the side of the blast tube. Disconnect thehigh voltage ignition cable by pulling it straight back, awayfrom the pilot assembly. The pilot assembly will slide backand away from the diffuser. Turn the assembly and retracit through the access hole. Check the electrode position asillustrated in Figure 4-1. Reassemble in reverse order.

Measure the position of the tip of the nozzle to the diffuse

and compare to the following drawer assembly drawingsAdjust as follows:1. Loosen the locking screws on the diffuser clamp.2. Slide the diffuser clamp along the length of the burnerpipe 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 beforetightening.4. Carefully install the drawer assembly into the burner.Re-connect the oil line and high voltage power cable toassembly.

Measure the position of the diffuser to air baffle and

compare to the following drawer assembly drawings. Adjusas follows:1. Measure the distance between the leading edge of thediffuser and the front face of the inner ring on the air baffleassembly.2. If adjustment is required, loosen the burner pipe lockingsetscrew located on the rear cap at the top of the fanhousing, and slide the burner pipe until the correctdimension is achieved.3. Tighten the burner pipe locking setscrew securely.

Size 1 & 2 Gas Pilot

Figure 4-1

Size 3 & 4 Gas Pilot

10-3/4"

ELECTRODE END

WITHIN 1/4"

FROM TUBE END

TIP TO TUBE

GAP OF 1/8"

656-00016

TIP TO TUBE

GAP OF 1/8"

656-00017

11"

ELECTRODE END

WITHIN 1/4"

FROM TUBE END

AN ULTRA-VIOLET FLAME SENSOR ELECTRI-CAL SPARK INTERFERENCE TEST MUST BE

PERFORMED AFTER FINAL ADJ USTMENT. SEESECTION 3 OF THIS MANUAL FOR ADDITIONALINFORMATION.

WARNING

7/28/2019 V Manual

34/51

32

Direct spark ignition

Size 1, VL-13 to 34

Size 1, VLG-13 to 34

Size 1, VG-13 to 34

Figure 4-3

656-00019

2-1/16" REAR FACEOF DIFFUSER TO

FRONT FACE OFAIR BAFFLE

656-00020

1/8" BETWEEN

INNER EDGES OF

ELECTRODE WIRES

2-1/16" REAR FACE

OF DIFFUSER TO

FRONT FACE OF

AIR BAFFLE

1/8" FROM

NOZZLE TIPTO REAR FACE

OF DIFFUSER

1/4" FROM

NOZZLE TIP TO

OUTER EDGE OF

ELECTRODE WIRES

7/16" FROM

CENTER OF NOZZLE

TO BOTTOM OFELECTRODE WIRES

13/16" FROM

NOZZLE TIP

TO REAR FACE

OF DIFFUSER

2-1/8" REAR FACE

OF DIFFUSER TO


656-00021

Size 2 VG-35 to 55

Size 2, VLG-35 to 55

656-00022

2-1/2" REAR FACE

OF DIFFUSER TOFRONT FACE OF

AIR BAFFLE

656-00023


FRONT FACE OF

AIR BAFFLE

1/2" FROM

NOZZLE TIP

TO REAR FACE

OF DIFFUSER

Figure 4-4

Size 3, VLG-60 to 110Figure 4-5

656-00024

2-1/2" REAR FACE

OF DIFFUSER TO

FRONT FACE OF

AIR BAFFLE

Size 3, VG-60 to 110

656-00025

13/16" FROM

NOZZLE TIP

TO REAR FACE

OF DIFFUSER

2-7/16" REAR FACE

OF DIFFUSER TO

FRONT FACE OF

AIR BAFFLE

1/4" FROM

NOZZLE TIP TO

OUT ER EDG E OF

ELECTRODE WIRES

1/8" BETWEEN

INNE R EDGES OF

ELECTRODE WIRE S

7/16" FR OM

CENTER OF NOZZL E

TO BOTTOM OF

ELECTRODE WIRE S

656-00 018

Figure 4-2

7/28/2019 V Manual

35/51

33

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

Refer to the flame safeguard control manual instruc-

tions.

3. Check theflame signal strength. Adjust theflame signalby increasing or decreasing pilot gas pressure with theregulator spring. Normal setting is 4 w.c. to 6 w.c.4. Perform a pilot turndown test by reducing the pilot pres-sure very slowly until the scanner looses sight of theflame and give a flame lock-out, than reset the adjustment to normal level. Note the minimum pressure level.5. After adjusting the pressure back to normal level, set theprogrammer to the Run position. Mainflame will come

on and the burner is in the low fire position.6. Start and stop the burner several times to ensure properpilot setting.

G.ON-OFF BURNER ADJUSTMENTS Refer to the burner data plate located inside the controlpanel 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 pressureto get the correct manifold pressure at maximum firing

rate.).

These procedures assume that the pre-start-up taskscheck list, electrical interference test, and pilot turn-downtests, have been performed in accordance with the instructions in this manual.

Allow boiler to fully warm up before making adjustmentsfor most efficient combustion. Refer to the boiler instructionmanual for the boiler controls settings.

GAS BURNERS

On-Off gas burners are typically equipped with a pressure regulator, and a solenoid operated diaphragm gasvalve to control the on-off operation of the burner. Adjustments 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 andthe pressure downstream of the regulator. Make surethey are in accordance with the regulator specifications.

The gas pressure required at the manifold is the pressurethat is required to fire the burner at its rated capacity. Toadjust 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. Turn the burner switch to the ON position.4. Adjust the burner for a smooth ignition of the mainflame

The bleed valve adjustment controls the opening of theV48 valve. When the controller is not calling for heat, the

coil is de-energized. The plunger in the 3-way actuator isin the DOWN position so the bleed port is closed and thesupply port is open. Gas flows into the top part of thevalve. The gas pressure on top of the diaphragm, theweight, and the spring hold the valve closed. On call forheat, the controller contacts close and the coil is ener-gized. This pulls the plunger to the UP position, openingthe bleed port and closing the supply port. The gas in thetop of the valve flows out through the bleed port. Thisreduces the pressure on top of the diaphragm, allowingthe gas pressure below to lift the diaphragm and open thevalve.5. Adjust the highfire gas input to match maximum ratingAdjust the gas regulator so the manifold pressure matchesthe rating on the burner data plate. Verify and record youreadings and pressures. High fire is typically 3.0 to 4.0 %O2 with a target value of less than 50 ppm CO.

The burner should be adjusted to provide correct fueflow at a constant rate, as indicated on the burner dataplate. This is achieved by clocking the gas flow at the gasmeter. The gas utility or gas meter calibration data, shouldbe consulted to determine the correction factors to be ap

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

656-09522-000



656-009523-000

1/4" FROM

NOZZLE TIP

TO REAR FACE

OF DIFFUSER

2-7/8" REAR FACE

OF DIFFUSER TO

FRONT FACE OF

AIR BAFFLE

Size 4 VG 60 to 168

Size 4 VLG 60 to 168

Figure 4-6

7/28/2019 V Manual

36/51

34

plied to the meter.

Natural Gas Input Calculation Using a Meter

HHV = Higher heating Value Of Gas, Btu/ft3 (if no data is

available, use 1000

CF = Cubic Feet of Gas Clockedt = Gas Meter Clock Time, seconds

Pm

= Meter Upstream pressure (see Pref

for units)

Pb

= Barometric Pressure (See Pref

for units)

Pref

= 14.696 psi, or29.92 HG, or 406.77 w.c.

Tref

= Gas reference Temperature, oF (Use 77 if data

unavailable)

Tg

= Gas Temperature at meter, oF

6. After completing all adjustments, replace the regulatorgaskets and slotted aluminum screw cap.Tighten alllinkages 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 pumpmodel. High fire pressure adjustment is 200-300 PSI(solenoid energized), and lowfire pressure adjustment is100-200 PSI (solenoid de-energized).1. Briefly push in the starter contact and release to ensurethat the blower motor and oil pump are rotating in thecorrect direction.2. Turn the burner switch to the ON position.3. Make sure a pressure gauge, 0-600 PSI range, is installed, downstream of the solenoid valves. Adjust the

burner for a smooth ignition of the mainflame. Disconnect the wiring to the solenoid on the Suntec B2TC-8931oil pump. Loosen and remove knurled nut on the solenoid. Adjust the screw, clockwise to increase lowfire oilpressure, and counterclockwise to decrease the lowfireoil pressure, until a smooth ignition of the oil flame isobtained and a satisfactory lowfire oilflame is established.

Turn burner off and restart to ensure smooth ignition isobtained at the set lowfire pressure. Replace knurled nutand tighten finger tight.4. Adjust the highfire oil input to match the maximum rat-ing. Turn the burner off and reconnect the wiring to thesolenoid valve. Restart the burner and allow burner to gothrough ignition and lowfire. When the solenoid energizes,the oil pump discharge pressure is at high fire pressure.

The highfire pressure adjustment screw is located on theoil pump body. Adjust the screw, clockwise to increase thepressure and counterclockwise to decrease the pressure,until correct amount of oil pressure is obtained. The highfireoil pressure should be 300 PSI. High fire is typically 3.5%to 4.5% O2, with less than a No.1 smoke. The burnershould be adjusted to provide the correct amount of fuelflow at a constant rate at highfire 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 startedfirst using oil, because as a fuel, oil has a greater combus-tion air requirement than natural gas. After being completelyadjusted for oil combustion, the burner is re-started andadjusted using natural gas as fuel. Combustion adjustmentof the combination burner for natural gas involves balancing

the input rate only against the existingflow of combustionair, 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 using the sameprocedures defined in the Oil Burners section.4. After the system has been completely adjusted for oilfiring, place the burner switch OFF, and position thefuel selector switch to GAS.5.Proceed with start-up and adjustments using the sameprocedures defined in the Gas Burners section. Do not

alter the air settings set for oil.Note

For burners equipped with a Siemens modulating motor,fuel/air adjustments for each fuel are independent on eachother. Refer to Siemens modulating motor product literaturefor proper adjustment.

H. LOW-HIGH-OFF & LOW-HIGH-LOWBURNER ADJUSTMENTS

Refer to the burner data plate located inside the controlpanel 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 pressureto get the correct manifold pressure at maximum firingrate).

These procedures assume that the pre-start-up tasks,check list, electrical interference test, and pilot turn-downtests, have been performed in accordance with the instruc-tions in this manual.


GAS BURNERS

The gas burner adjustments on a Low-High-Off systemconsist of the gas pressure regulator, gas butterfly valve,low and high gas pressure switches, and air damper as-sembly.

The auxiliary switch inside the M436 Mod motormakes or breaks the High fire gas. See Fig.10 for switchadjustment. The Low-High-Low boiler control energizesthe M436 motor, driving it to high fire. When the boilercontrol denergize the M436, a built in return spring drivesit to the lowfire position.

All VG-13 to 55 use a butterfly gas valve to control the

460( / ) 3600

460

refm b

ref g

TP PcfInput Btu hr HHV

t P T

++=

+

7/28/2019 V Manual

37/51

35

gas flow to the burner. The M436 Mod motor controls theposition of the valve.1. Open the manual gas shut-off cocks.2. Check the gas pressure at the inlet of the regulator andthe pressure downstream of the regulator. Make surethey are in accordance with the regulator specifications.

The gas pressure required at the manifold is the pressurethat is required to fire the burner at its rated capacity. Toadjust 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. The burner will start and be in the lowfire position.5. After a few seconds, the O

2analyzer should have an

accurate reading of the O2

present in the flue gas. Nor-mally, O

2levels are set between 4 to 6 percent at low fire

for standard turndown systems on gas and 6 to 9% O2 forhigh turndown systems, with the target value of less than50 ppm CO. To obtain the proper readings, adjust the airshutter and lowfire regulator pressure.6. Operate the boiler at lowfire until it is up to operatingpressure (steam) or temperature (hot water).

7. Bring the burner to the highfire position. Adjust the highfire gas input to match maximum rating. At high fire, thebutterfly valve should be near the full open position. Adjustthe gas regulator so the manifold pressure matches therating on the burner data plate. Verify and record yourreadings and pressures. High fire is typically 3 to 4% O

2

with less than 50 ppm CO.8. Adjust the low and high gas pressure switches byturning the adjusting screw until indicator moves to apressure slightly lower than normal operating pressurefor the low gas pressure switch, and slightly higher for thehigh gas pressure switch (usually 20% below and 20%higher than normal pressure).

9. Verify low fire and high fire rate by clocking the meteras previously explained.10. After completing all adjustments, replace the regulatorsgaskets and slotted aluminum screw caps.Tighten alllinkages and marked settings. Complete the Start-upreport at the end of this section.

The burner should be adjusted to provide correct fuelflow at a constant rate, at the lowfire and highfire positionas indicated on the burner data plate. This is achieved byclocking the gasflow at the gas meter. The gas utility or gasmeter calibration data, should be consulted to determinethe correction factors to be applied to the meter.

Natural Gas Input Calculation Using a Meter

HHV = Higher heating Value Of Gas, Btu/ft3 (if no data is

available, use 1000

CF = Cubic Feet of Gas Clocked

t = Gas Meter Clock Time, seconds

Pm

= Meter Upstream pressure (see Pref

for units)

Pb

= Barometric Pressure (See Pref

for units)

Pref

= 14.696 psi, or29.92 HG, or 406.77 w.c.

Tref

= Gas reference Temperature, oF (Use 77 if data

unavailable)

Tg

= Gas Temperature at meter, oF

OIL BURNERS

The Suntec B2TD-8842 oil pump is typically incorporatedand is a two-stage, two step oil pump. The low fire pressure adjustment is 100-200 PSI (solenoid de-energized)High fire pressure adjustment is 200-300 PSI (solenoidenergized).1. Turn the burner switch to the ON position.2. Adjust lowfire with the oil pressure regulating valve tohave approximatly 100 to 200 PSI, and adjust the airshutter for a cleanfire. Record your combustion readingfrom the flue gas analyzer, normally 3.5 to 4.5 percent O

and less than No.1 Smoke (Bacharach). To adjust the oipressure regulating valve, remove lockscrew and adjustpressure by turning the allen screw clockwise to increasepressure, and counterclockwise to reduce pressure.3. Operate the boiler at lowfire until it is up to operatingpressure (steam) or temperature (hot water).4. Adjust the highfire fuel input to match maximum oilpressure. At high fire, the pressure should be 300 PSI.Verify and record your readings and pressures. Highfireis typically 3.5 to 4.5% O

2with less than No.1 smoke.

The burner should be adjusted to provide correct fuelflow at a constant rate, at the lowfire and highfire positionas indicated on the burner data plate.

5.Tighten all linkages and marked settings. Complete theStart-up report at the end of this section.

COMBINATION GAS-OIL BURNERS

In general, the combination fueled system is to be startedfirst using oil, because as a fuel, oil has a greater combustion air requirement than natural gas. After being completelyadjusted for oil combustion, the burner is re-started andadjusted using natural gas as fuel. Combustion adjustmenof the combination burner for natural gas involves balancingthe input rate only against the existingflow of combustionair, 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 sameprocedures defined in the Oil Burners section.4. After the system has been completely adjusted for ofiring, place the burner switch OFF, and position the fuelselector switch to GAS.5. Proceed with start-up and adjustments using the sameprocedures defined in the Gas Burners section. Do not

460( / ) 3600

460

refm b

ref g

TP PcfInput Btu hr HHV

t P T

++=

+

7/28/2019 V Manual

38/51

36

alter the air settings set for oil. Correct your O2levels by

adjusting the butterfly valve for Size 2 models, and theregulators low and high pressures for Size 1 models.

I. FULL MODULATION BURNERADJUSTMENTSRefer 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 manifoldpressure (at zero furnace pressure. Add the furnace pres-sure to get the correct manifold pressure at maximumfiringrate.).

These procedures assume that the pre-start-up tasks,check list, electrical interference test, and pilot turn-downtests, have been performed in accordance with the instruc-tions in this manual.


GAS BURNERS

The gas burners adjustments on a full modulation burnerconsist of the gas pressure regulator, butterfly gas valve,low and high gas pressure switches (Model V30-168), andair dampers.1. Open the manual gas shut-off cocks.2. Check the gas pressure at the inlet of the regulator andthe pressure downstream of the regulator. Make surethey are in accordance with the regulator specifications.

The gas pressure required at the manifold is the pressurethat is required to fire the burner at its rated capacity. Toadjust the regulator, unscrew the cap located on top andturn 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 theCLOSED (Low Fire) position.5. Turn the burner switch to the ON position.6. The burner will start and be in the lowfire position.7. After a few seconds, the O2 analyzer should have anaccurate reading of the O2 present in the flue gas. Nor-mally, O2 levels are set between 4 and 6 percent at lowfire on standard turndown systems and 6 and 9 % on highturndown systems, with less than 50 ppm CO as a targetvalue. To obtain the proper readings, adjust the gas but-terfly opening and air shutters. Take note of the readingsand pressures at the burner manifold and gas train.8. Operate the boiler at lowfire until it is up to operatingpressure (steam) or temperature (hot water). Then in-crease the fuel input to the boiler by turning the manualflame control potentiometer towards OPEN in smallincrements. This will cause the butterfly valve to

Documents

V Manual