Can-Eng Furnaces International Limited

Heat Treatment Equipment

Natural Gas Fired
Combustion Systems
Booklet

Can-Eng Furnaces International Ltd.

6800 Montrose Road
P.O. Box 628
Niagara Falls, ON, Canada L2E 6V5

© Can-Eng Furnaces International Ltd.- 2011

 Can-Eng Furnaces International Limited - Heat Treatment Equipment
Natural Gas Fired
Combustion Systems Booklet

Table of Contents

1 GENERAL..........................................................................................................................................................3
1.1 Introduction ................................................................................................................................................3
1.2 Deviations from Design and Intended Usage .............................................................................................3
2 HEAT TRANSFER............................................................................................................................................4

3 COMBUSTION SYSTEMS ..............................................................................................................................4

4 TYPE OF BURNER CONTROL .....................................................................................................................5

5 MAINTENANCE LOGS...................................................................................................................................5

6 TESTING OF SAFETY SHUTOFF VALVES................................................................................................6

6.1 Weekly Safety Shutoff Valve Leak Test Procedure ...................................................................................7
6.2 Monthly Safety Train Interlock Integrity Test Procedure ..........................................................................8
7 COMBUSTION SYSTEM SAFETY TRAIN COMPONENTS ....................................................................9
7.1 Normally Open Vs. Normally Closed Valves ...........................................................................................9
7.2 Combustion Safety Train............................................................................................................................9
7.3 Low Gas Pressure Switch.........................................................................................................................10
7.4 High Gas Pressure Switch ........................................................................................................................10
7.5 Purge Timer ..............................................................................................................................................11
7.6 Over Temperature Instrument ..................................................................................................................11
7.7 Safety Shut Off Valve with Proof-Of-Closure Auxiliary Switches..........................................................11
7.8 Automatic Vent Valve ..............................................................................................................................12
7.9 Automatic Block Valve ............................................................................................................................12
7.10 Low Air Pressure Switch..........................................................................................................................12
7.11 Recirculation Fan - Proof of Operation ....................................................................................................13
8 COMBUSTION SYSTEM HARDWARE .....................................................................................................14
8.1 Remote Fuel Shutoff Valve ......................................................................................................................14
8.2 Main Fuel Isolation Valve ........................................................................................................................14
8.3 Fuel Filter .................................................................................................................................................14
8.4 Appliance Regulator.................................................................................................................................14
8.5 Manual Isolation Valve ............................................................................................................................14
8.6 Burner Block Valves ................................................................................................................................14
8.7 Ratio Regulators .......................................................................................................................................15
8.8 Burner Fuel Trim Valve ...........................................................................................................................15
8.9 Burner Firing Valve..................................................................................................................................15
8.10 Manual Block Valve.................................................................................................................................15

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8.11 Gas Metering Orifice................................................................................................................................15
8.12 Spark Generators ......................................................................................................................................16
8.13 UV Scanners.............................................................................................................................................16
8.14 Flame Rods...............................................................................................................................................16
8.15 Flame Relays ............................................................................................................................................17
8.16 Combustion Air Blower ...........................................................................................................................17
8.17 Combustion Air Supplies .........................................................................................................................17
8.18 Motorized Air Control Valve ...................................................................................................................17
8.19 Air Trim Valve .........................................................................................................................................18
8.20 Air Metering Orifice.................................................................................................................................18

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1 GENERAL

1.1 Introduction

The general intent of this booklet is to provide basic heat treat equipment combustion system
information to operators and maintenance personnel. This booklet must be read with both the
equipment Operation and Maintenance Manual and the Safety Booklet. The Operation and
Maintenance Manual is written specifically for your equipment. All other booklets are general
equipment guides.

If you should have any question contact Can-Eng Customer Support and Technical Services.

Phone: 1-905-356-1327
Fax: 1-905-356-3404
e-mail: furnaces@can-eng.com
website: http://www.can-eng.com

1.2 Deviations from Design and Intended Usage

CAN-ENG equipment is designed for original intended usage with safety in mind. Changing
either the combustion design without prior written authorization from CAN-ENG FURNACES
INTERNATIONAL LTD. may result in the risk of unsafe operation and voiding the warranty.
CAN-ENG will attempt to work with you if there is some aspect of the equipment that does not
function properly in your application, within the limits of safety and the equipment’s intended
usage. It should be remembered, however, that many aspects of the design are dictated by safety
considerations and should not be changed.

Any equipment supplied with a programmable controller should not be worked on by anyone not
trained in the use and operation of programmable controllers. No attempt should be made to re-
program any programmable control without written authorization from CAN-ENG FURNACES
INTERNATIONAL LTD. Re-programming without full knowledge of the addresses used in the
original program can result in possible dangerous operation, such as lack of temperature control
or uncontrolled machine movement.

Extreme care must be used in applications where it is necessary to use a programming panel to
troubleshoot a programmable controller. Improper commands can create uncontrolled machine
movement or interfere with the machine memory. Do not permit untrained personnel to use a
programming panel.

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2 HEAT TRANSFER

Heat is transferred to a load by three means:

1) CONDUCTION - heat is transferred between two objects that are in contact with each
other by conduction.
2) CONVECTION – heat is transferred between a solid and a gas (metal and air or special
atmosphere). Natural convection occurs when heat creates a natural current or flow of the
gas. Forced convection is when the current is created by mechanical means (a fan).
3) RADIATION – heat is transferred in a straight “line of sight” from a red hot surface through
the gas or medium to the object.

A combination of all three methods of heat transfer are used in varying degrees on most systems.
Radiation does not play a great part in low temperature ovens.

3 COMBUSTION SYSTEMS

Combustion or burning is the rapid combination of a fuel with oxygen resulting in the release of
heat. Three components are required to achieve successful combustion:
1) a fuel (natural gas) , mixed at the proper ratio with
2) oxygen (air) , ignited by a source of
3) heat (spark).

The oxygen : fuel ratio must be mixed within the ignition limits know as the Lower Explosive Limit
(LEL) and Upper Explosive Limit (UEL). This ratio for air : natural gas is from 4:1 to 14:1. The
stoichiometric or ideal ratio for theoretically complete combustion is 10:1. Most combustion
systems are set up to run with some excess air (XSA) to assure complete combustion of the fuel is
achieved. This XSA setting can be at 10% or 15%.

As air is comprised of 21% oxygen:

10% XSA yields 2.1% additional oxygen.
15% XSA yields 3.0% additional oxygen.
25% XSA yields 4.6% additional oxygen.
50% XSA yields 7.5% additional oxygen.
100% XSA yields 11.1% additional oxygen.

Some systems are designed to operate with huge amounts of XSA, possibly as much as 150%. This
results in quenching the flame and makes extremely low operating temperature control possible.

There are basically two types of burner systems, i) pre-mixed systems and ii) nozzle mixed systems.
This refers to where the fuel and oxygen are mixed at the proper ratio prior to igniting the mix.
Nozzle mixed burners are mixed in the burner at or in the burner nozzle. Gases of a premixed system
are mixed prior to the flow reaching the burner body.

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4 TYPE OF BURNER CONTROL

Your equipment Operation and Maintenance Manual will describe in detail the type of burner
control supplied with your equipment.

5 MAINTENANCE LOGS

Can-Eng actively encourages its customers to use Equipment Logs for each major component of
a heat treating installation. These Logs, if kept correctly and consistently, become a significant
item in the equipment's maintenance programs as they contain a record of the original
commissioning settings and operating parameters plus what may have been modified due to
operating or service experience.

Logs can be used for troubleshooting, resetting back to original conditions, determining life
histories of consumable components, recording calibrations and test results and establishing a
complete running record of the equipment. It is strongly suggest that the customer create a Log
Book or electronic sheet to record annual, semi-annual or more frequent checks to keep track of
the equipment settings that can then be compared to original settings throughout the life of the
equipment.

Suggested information to be logged:

 Appliance regulator inlet and outlet pressure settings

 High gas pressure switch setting
 Low gas pressure switch setting
 Results of weekly Safety Train Valve Sealing Integrity Tests (dated and signed)
 Results of Monthly Safety Train Interlock Integrity Test (dated and signed)
 Burner gas High Fire chest pressure
 Burner air High Fire chest pressure
 Combustion air blower discharge pressure
 Combustion air blower motor current (amp draw)
 Date combustion blower filter changed/cleaned
 Problems and corrective actions (dated and signed)

If you have a multiple burner system record settings for each individual burner/blower.

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6 TESTING OF SAFETY SHUTOFF VALVES

Fuel is supplied to natural gas fired combustion systems through a “safety train” consisting of a
manual isolation valves, main appliance gas pressure regulator, automatic gas shut off valves and
gas pressure switches and possibly vent valves.

The Fuel Safety Train protects the system and personnel from the development of dangerous
situation that might result in a deadly explosion. When closed the safety shut off and automatic
block valves properly isolates fuel flow to the equipment. If the equipment requirements
necessitate a large fuel flow, as dictated by codes, a vent valve will be supplied to safely vent
any leakage past the shutoff valve to outside the building.

These systems must be leak tested as described below. Some systems are supplied with an
electronic module leak tightness device that automatic tests for leaks every time the system is
started up. If your equipment has this device you need only do the following manual test once a
year. Your equipment Operation and Maintenance Manual will advise if your equipment has this
module.

Safety Train Valve Sealing Integrity Tests For a Double Block and Bleed System

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 6.1 Weekly Safety Shutoff Valve Leak Test Procedure

The following test must be conduct regularly on a weekly basis and the results of the test are to
be recorded (dated and signed) and kept on file.

Unless already installed, mount approved test cocks immediately downstream of the Safety Shut
Off Valve and the Auto Block Valve. Procure suitable lengths of flexible tubing and water
containers. Connect the tubing to the valves and run them to containers of water. Unless
otherwise installed, mount a Pressure Gauge immediately downstream of the Appliance
Regulator.

1) With the Burners operating normally, depress and hold the Leak Test Pushbutton (aka
Deadman Switch). The Leak Test Pushbutton, when depressed, forces the N.O. (normally open)
Vent Valve to stay closed. With the Safety Shutoff Valve and the Auto Block Valve shut, this
action blocks the escape of fuel between the solenoid.

2) Quickly close the Manual Block Valve. On systems with Total Fuel Outage, upon flame
failure the Safety Shutoff Valves will immediately close. On systems with no flame failure, or
with single burner outage, it will be necessary to manually close the Safety Shutoff Valve. Once
the Safety Shutoff Valve is shut the Auto Block Valve will close automatically.

3) Make sure the Safety Shutoff Valve and the Auto Block Valve both indicate closed. Also
ensure that the tubing is (i) connected to test cocks, (ii) terminate in the bucket of water. The
Pressure Gauge must show pressure.

4) Slowly crack open the test cock downstream of the Auto Block Valve. This will vent the gas
trapped between the Auto Block Valve and the Manual Block Valve. Do not rush this
depressurizing process.

5) Once the volume is vented, fully open the test cock downstream of the Auto Block Valve. If
bubbles continue to appear then the Auto Block Valve is not sealing and it requires servicing.

6) Close the test cock downstream of the Auto Block Valve.

7) Slowly crack open the test cock downstream of the Safety Shut Off Valve. This will vent the
gas trapped between the Safety Shut Off Valve and the Auto Block Valve. Do not rush this
depressurizing process.

8) Once the volume is vented, fully open the test cock downstream of the Safety Shut Off Valve.
If bubbles continue to appear then the Safety Shut Off Valve is not sealing and it requires
servicing.

9) Close the test cock downstream of the Safety Shut Off Valve.

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10) Release pressure on the Leak Test Pushbutton. If Safety Valve service is required, make
sure that the upstream and downstream Manual Valves are closed. Depressurize any trapped
fuel before opening any components. Follow the Valve manufacturer’s repair techniques
carefully. If in doubt, contact personnel knowledgeable in the service of this equipment.

11) A FULL LEAK TEST MUST BE CARRIED OUT FOLLOWING ANY SAFETY
VALVE SERVICE.

12) Open the Manual Block Valve, close all test cocks, and remove the tubing before re-igniting
the burners.

13) Maintain a log that records each test, the date performed, by whom, what were the results,
and maintenance done (including personnel involved and materials used).

6.2 Monthly Safety Train Interlock Integrity Test Procedure

The following test must be conduct regularly on a monthly basis and the results of the test are to
be recorded and kept on file.

1) With the burners operating normally, close the Main Fuel Isolation Valve. The Safety Shut
Off Valve and the Auto Block Valve should close immediately due to loss of fuel as detected by
the Low Gas Pressure Switch.

2) With the burners operating normally, lower the set point of the High Gas Pressure Switch to
the pressure in the Safety Train. At this point the Safety Shut Off Valve and the Auto Block
Valve should close immediately due to the apparent high fuel pressure. Reset the High Gas
Pressure Switch to its correct level after this test.

3) With the burners operating normally, shut off the Combustion Air Blower. The Safety
Shutoff Valve and the Auto Block Valve should close immediately due to loss of combustion air
pressure as detected by the Low Air Pressure Switch.

4) Refer to the system’s electrical schematic and list all burner interlocks (aside from the High
and Low Gas Pressure and the Low Combustion Air Pressure). Test each interlock while the
burners are operating normally. These tests should include: over temperature limit controls, low
compressed air pressure, recirculation fans, et al. Failure of any of these tests (including High
and Low Gas Pressure and the Low Combustion Air Pressure) should cause the unit to be taken
out of service until the fault is corrected. Failure to observe this precaution can result in a
dangerous condition that could lead to an explosion or fire.

6) Maintain a log that records each test, the date performed, by whom, what were the results, and
maintenance done (including personnel involved and materials used).

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7 COMBUSTION SYSTEM SAFETY TRAIN COMPONENTS

7.1 Normally Open Vs. Normally Closed Valves

Throughout the combustion industry the terms “Normally Open” and “Normally Closed” are
used to describe valves and switches. These terms are often a source of confusion because they
seem to imply the opposite of what they are. In this case “Normal” means “no power”.
Normally Open means open when there is no power. Normally Closed means closed when there
is no power.

Normally Closed valves are used to control fuel flow. When there is a call for heat then power is
supplied and the valve opens. If there is an alarm, or if there is a power failure, then the power is
shut off and the valve closes. The confusion comes because during normal operation a
Normally Closed valve is open and a Normally Open valve is closed. The dual use of the term
“normal” can cause misunderstandings. Since these valves go to their Normal condition when
there is an alarm or a power failure, it is best to think: Normally Open is Fail Open, and
Normally Closed is Fail Closed. These valves are clearly identified on piping schematics with
the abbreviation NO or NC.

7.2 Combustion Safety Train

There are a number of hardware items installed that collectively form what is known as the
“safety train”. These items have electrical connections and collectively create a circuit which
must be complete before the burners can be fired, and in most cases remain operational. During
initial ignition, if any of the conditions are not met, the combustion system cannot be started. If
the system is already operating and any of the conditions fail, it will be shut down and an alarm
will sound.
These items include:
1. Low Gas Pressure Switch
2. High Gas Pressure Switch
3. Purge Timer
4. Over Temperature Instrument
5. Safety Shut Off Valve
6. Automatic Vent Valve
7. Automatic Block Valve
8. Low Air Pressure Switch
9. Recirculation Fan, operation monitoring

The function, operation and setting requirements of these items are discussed in the following
sections.

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 7.3 Low Gas Pressure Switch

A Low Gas Pressure Switch is used to monitor the pressure of the natural gas downstream of the
pressure regulator. The switch is wired as a normally open type, which means that power will not
pass through the switch unless the contact closes. To make the contact close, the switch must detect
fuel pressure at or above the set point of the switch.

The switch used is a manual reset type, which means that operator intervention is required to make
the switch. When gas pressure is applied at a pressure equal to or greater than the set point, the
switch will not close without the operator resetting it. To provide safe operation, the switch is set at
the minimum pressure required to operate the equipment.

At the start-up stage, the main gas supply valve must be opened manually to allow the switch to
detect pressure and then the operator can set the switch. If the inlet pressure is below the set point of
the switch, the switch will not close even with the operator manually resetting it. The electrical
circuit will be incomplete, and the safety shutoff valve cannot be opened to allow gas to the
combustion system.

During operation, if the pressure falls below the setting of the switch, then the electrical circuit will
be broken, causing the safety shutoff valve to close and cut off the gas supply.

7.4 High Gas Pressure Switch

A high gas pressure switch is used to monitor the pressure of the natural gas downstream of the
pressure regulator. The switch is wired as a normally closed type, which means that power will pass
through the switch as long as the contact remains closed. To keep the contact closed, the switch
must detect fuel pressure at or below the set point of the switch.

The switch used is a manual reset type, which means that operator intervention is required to make
the switch. To provide safe operation, the switch is set at the maximum pressure allowed to operate
the equipment.

At the start-up stage, the main gas is initially closed and gas pressure at the switch is zero. With
pressure below its set point, the switch can be set to its closed position.

During operation, the switch will remain closed unless the gas pressure rises above the set point of
the switch. Once the pressure rises above the set point, the switch will open, the electrical circuit
will be incomplete and the safety shutoff valve will shut. With the gas supply shut off the pressure
will drop, but the High Gas Pressure Switch will stay open until it is manually closed.

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 7.5 Purge Timer

As part of a safe start-up procedure, regulations require the “purging” of the areas of the unit where
combustion will take place, prior to the admission of natural gas. The length of the purge cycle is
based on the volume of the combustion area and the number of required volume changes.

The purge timer is the last item in the circuit that feeds power to the safety shut off valve. When all
of the conditions are met to power the timer, the time-out cycle starts. When the time-out cycle is
finished, the contact in the timer switches and powers the safety shut off valve.

THE SETTING OF THE PURGE TIMER SHOULD NEVER BE ALTERED.

CHANGING THIS SETTING MAY CAUSE DANGEROUS OPERATING CONDITIONS

AND POSSIBLE INJURY TO PERSONNEL.

7.6 Over Temperature Instrument

The furnace is provided with an Over Temperature Instruments and thermocouple(s). The
purpose of these instruments is to protect the equipment from being damaged by an excess
temperature condition. Normally the over temperature device is set 100F above the control
instrument set point. For example, if the temperature controller has a set point of 850F then the
over temperature instrument would have a set point of 950F.

The instrument is configured for “upscale burnout” which means that if a thermocouple fails (or
the circuit opens), the display will automatically run to its highest number thus tripping the
alarm. Under normal circumstances the only keys used are:
1. ‘DISPLAY’ - to alternately view set point and actual temperature.
2. The ‘UP’ and ‘DOWN’ arrow keys to adjust the set point. Note that the set point
must be displayed to make the arrow keys active.

7.7 Safety Shut Off Valve with Proof-Of-Closure Auxiliary Switches

The Safety Shut Off Valve is the heart of the “safety train” on the unit’s combustion system. Its
function is to automatically isolate the flow of natural gas to the burners whenever any one of the
other components detects an unsafe operating condition. This valve is a normally closed,
manually reset type valve that in a de-energized state does not allow fuel to flow through it.

All of the safety devices in the electrical circuit must be proven that they are within their defined
operating parameters before the electrical circuit becomes complete and allows the valve to be
opened. This is referred to as the ‘safety interlocks’. Operator intervention is required to open

11
the valve even when all conditions are met. This is accomplished by swinging the handle up and
away from you and then pulling it back towards you. Once latched in, the valve is then held
open by electric power. A visual indicator is provided on the valve to show if it is open or
closed.

A loss of power or a failure of any one of the other safety interlock devices in the circuit will
cause the valve to close. The safety shutoff valve is also equipped with an auxiliary switch that
controls the operation of the Automatic Block Valve and the Automatic Vent Valve discussed
below.

7.8 Automatic Vent Valve

An automatic Vent Valve is supplied when fuel volume necessitates the need as dictated by code.

The Automatic Vent Valve is located between the Primary and Secondary Safety Shut Off Valves.
This valve is a “normally open” type, which during ordinary operations is electrically held closed.
The purpose of this valve is to vent any gas that would otherwise be held between the Safety Shut
Off Valves during a shutdown. When power is removed from the valve, it opens and vents any gas
trapped in the line.

This combination of two SSOV’s (Safety Shut Off Valves) and an Automatic Vent Valve is
referred to as a “Double Block & Bleed” system.

Although the Vent Valve is a part of the Main Safety Train, it does not send any signals to the
system. A failure of the Vent Valve will not cause a shutdown. For this reason it is important to
test the Vent Valve to ensure that it is operating correctly.

7.9 Automatic Block Valve

The Automatic Block Valve is located downstream of the Safety Shutoff Valve and the Safety
Shutoff Valve triggers its operation. The Automatic Block Valve is also a normally closed,
electrically held open valve, however it is an automatic reset type. An auxiliary switch located in the
Safety Shut Off Valve (SSOV) governs its operation. When the SSOV is opened, the auxiliary
switch is made, applying power to the Auto Block Valve, which then opens automatically. If the
SSOV closes, the auxiliary switch breaks and the Auto Block Valve closes. The purpose of this
valve is to provide a backup to the SSOV, isolating fuel flow to the system. Using two safety valves
is called a “Double Block”. With the addition of a Vent Valve this becomes what is called a
“Double Block & Bleed” system.

7.10 Low Air Pressure Switch

A Low Air Pressure Switch is used to monitor the pressure of the combustion air. The switch is
wired as a normally open type, which means that power will not pass through the switch unless the
contact closes. To make the contact close, the switch must detect air at or above the pressure set
point of the switch.

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The switch used is an auto-recycle type, which means that operator intervention is not required to
make (reset) the switch. When air pressure is applied at a pressure equal to or greater than the set
point, the switch will close without the operator resetting it. To provide safe operation, the switch is
set at the minimum pressure required to operate the equipment.

At the start-up stage, the combustion air blower is powered ON and the switch detects pressure.
Then the switch resets itself. If the inlet pressure is below the set point of the switch, the switch will
not close. The electrical circuit will be incomplete, and the safety shutoff valve cannot be opened to
allow gas to the combustion system.

During operation, if the pressure falls below the setting of the switch, then the electrical circuit will
be broken, causing the safety shutoff valve to close and cut off the gas supply.

7.11 Recirculation Fan - Proof of Operation

The operation of the circulation fan is vital to the heat transfer operation of the furnace and so must
be proved. Without proven operation of the fans, the purge timer will not start and ignition of the
burners will be prevented. During operation, a failure of the recirculation fans will cause the Safety
Shutoff valves in the gas line to close.

This can be done in two methods:

1. via air flow/pressure differential switch
2. via current monitoring

If your system uses an air flow or pressure differential (dP or ΔP) switch there will be nozzles on the
pressure and suction side of the fan flow to sense the fan is rotating and moving air.

If your system uses current monitoring on a fixed speed fan you may have a cosphi device and it
operates as follows:
To measure that a fan is operating correctly their “work” is monitored by a cosphi current
monitoring device. This devices will recognize a drop in current draw that might suggest the
motors are powered but the belts are broken resulting in the fan not turning (doing “work”).

If your system uses current monitoring on a variable speed fan that employs a variable frequency
controller (VFC ) the controller has current monitoring capabilities that operate similarly to the
cosphi device described above.

Your equipment Operation and Maintenance Manual will describe which method is employed.

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8 COMBUSTION SYSTEM HARDWARE

The following components are found downstream of the safety train.

8.1 Remote Fuel Shutoff Valve

This is a customer supplied manual valve. It is located far away from the combustion system so
that the gas can be shut off in the event of a fire at or near the equipment.

8.2 Main Fuel Isolation Valve

This is the first item in the gas supply line. It is located at the equipment. The purpose of this
valve is to isolate the entire system at one point. This valve is lockable to allow locking out the
combustion system for maintenance purposes.

8.3 Fuel Filter

A Fuel Filter is built into the Common Fuel Piping Rack. This filter ensures that no particles
(i.e. metal chips from thread cuttings) pass through and damage the system.

8.4 Appliance Regulator

A pressure-reducing regulator is provided on the natural gas supply line. The purpose of this
type of regulator is to lower and stabilize the natural gas supply line pressure to the level that is
required for combustion purposes by providing a constant outlet pressure.

Test points are provided both upstream and downstream of the regulator so that the pressures can
be verified.

8.5 Manual Isolation Valve

The Manual Isolation Valve is the first item in the individual burner gas lines. It allows the
operator to isolate each burner’s gas train and one of its uses is for leak testing.

8.6 Burner Block Valves

The natural gas to individual burners is turned on and off as required by the temperature
controller's call for heat. This is accomplished using a normally closed solenoid valve on each
gas line feeding a burner.

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This valve may be used to automatically isolate fuel flow to one burner if that burner has
experienced a loss of flame. The operator would have a limited number of attempts to re-ignite
the burner. There may also be a time limit on the window of opportunity to attempt a re-ignition.

8.7 Ratio Regulators

The natural gas flow to the burner is controlled using a “cross connected” Ratio Regulator. This
regulator is used to match the gas ratio and pressure to that of the combustion air pressure. This
is accomplished by the use of a tube run referred to as an “impulse” line. The impulse line is
connected from the main air header feeding the burner to the pressure tap on the regulator.

The amount of pressure from the air line works against a spring in the regulator to pass a
controlled flow of gas.

Note that the gas pressure at inlet of the ratio regulator must be higher than the air impulse
pressure at the inlet to the ratio regulator for the unit to function properly.

8.8 Burner Fuel Trim Valve

The burner is fitted with a limiting orifice valve on the natural gas line that is used to set the flow
of gas. This valve is equipped with a plug type cap that must be removed in order to operate the
adjustment. The adjustment consists of a simple screw that operates a needle type valve inside
the body. Turning the screw clockwise closes the valve while counterclockwise motion opens it.

8.9 Burner Firing Valve

The burner is equipped with a manual ball valve referred to as a “firing” valve. This valve is
used to allow the flow of gas to the burner when lighting it and can also be used to manually
isolate the flow of gas to the burner if required.

8.10 Manual Block Valve

The Manual Block Valve is the last item in the common part of the gas train. It allows the
operator to manually isolate the Safety Train from the rest of the gas train and one of its uses is
for leak testing.

8.11 Gas Metering Orifice

A metering orifice is either a separate device at or one built into to each Burner. By measuring
the pressure drop across the orifice plate an exact gas flow reading can be found.

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 8.12 Spark Generators

To provide the necessary high voltage required at the spark rod for ignition purposes, Spark
Generators are used. The Spark Generators are turned on whenever a call for heat is made by the
temperature controller.

To avoid the danger of electrical shock, extreme caution must be used due to the high
voltages present at the Spark Generators connection, the wire between the Spark
Generator and the Spark Rod itself.

Do not attempt to remove or install an ignition wire while power is applied.

Use a certified tester or turn the power at the control panel off before working in this area.

8.13 UV Scanners

Some burner systems are equipped with U/V (Ultra Violet) flame scanner detection devices on
the burners that monitor or proves flame ignition and existence. U/V scanners operate by sensing
the ultraviolet radiation emitted by the flame and thereby creating a millivolt DC current. They
have a self-checking capacity and ensure that the flame is truly on or off. If the flame
extinguishes the sensor signals the flame relay instantaneously which signals the PLC
programme resulting in fuel isolation to the burner or to the system, dependant on the system
design.

8.14 Flame Rods

Some burner systems are equipped with Flame Rod flame detection devices on the burners that
monitor or proves flame ignition and existence. Flame rods operate by sensing the heat created
by the flame and thereby creating a millivolt AC current between the rod and a ground. If the
flame extinguishes the sensor signals the flame relay (via loss of current) which signals the PLC
programme resulting in fuel isolation to the burner or to the system, dependant on the system
design. The electrode and porcelain insulator must be kept clean and dry to avoid nuisance
shutdowns.

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 8.15 Flame Relays

A Flame Relay unit is used in combination with a flame rod or U/V scanner on furnace burners
to ensure that there is a flame present and to prevent unsafe operating conditions. When the
necessary conditions have been met and an attempt is being made to light off the burner, the
flame relay turns on the ignition transformer to provide ignition and opens the gas solenoid for a
preset “trial for ignition” period. If no flame is detected within the trial for ignition period, the
flame relay shuts off the gas solenoid valve and the ignition transformer, sounds an alarm and
“locks out”. This then requires manual reset before another attempt to light the burner can be
made. If a flame is detected, the gas solenoid will remain open.

8.16 Combustion Air Blower

Combustion Air for burners are supplied by a Combustion Air Blower. There may be one blower
for multiple burners or one blower per burner, dependant on the type system supplied.

8.17 Combustion Air Supplies

Experience has proven that the majority of furnace environments are unsuitable as a source of
combustion air. In particular, large quantities of dirt and oil vapor are to be avoided at all times.

Foreign contamination will collect in combustion air passages and tends to reduce airflow, plug
controls, reduce blower efficiency, and lead to poor combustion. For these reasons, CAN-ENG
recommends that either
i) combustion blower inlets be ducted to a relatively contamination-free location using
economical light gauge metal duct of at least twice the diameter of the blower inlet,
or
ii) that washable or disposable mechanical filters be used.

Normally, ducting through an outside wall or through the roof is sufficient to satisfy most
requirements providing that the duct is not located near exhausters which are venting the very
materials that the duct is trying to avoid. Ducts that are run outside vertically should be
equipped with a cap to prevent objects from falling in and to keep out rain, etc.

If your company has a strong preventative maintenance program, then the use of mechanical
filters is acceptable. However, if the filters are overlooked or are removed as a nuisance the
problems mentioned above are inevitable.

8.18 Motorized Air Control Valve

The combustion air supply to burners is moderated by the temperature controller’s ‘call for
heat’. This is accomplished using a motorized butterfly valve. The connecting link between the
Motor and the Valve is set at commissioning so that the fully open position will exceed the

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required air for high fire. The modulation of the airflow is controlled by the Motorized Air
Control Valve, but the final setting of the high fire rate is controlled by an Air Trim Valve.

8.19 Air Trim Valve

The combustion air to the burners may be modulated by Motorized Air Control Valve, but an Air
Trim Valve allows the operator to trim –or set- the high fire air flow. The motorized air control
valve must be driven to high fire (full open) to accomplish this.

8.20 Air Metering Orifice

A metering orifice may be incorporated into each burner’s air inlet. By measuring the pressure
drop across the orifice plate an exact air flow reading can be found.

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NOTES

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