INSTALLATION & OPERATION C MANUAL POWER FLAME INCORPORATEDFOR YOUR SAFETY If you smell gas: Do not store or use gasoline or other 1. Open windows flammable liquids and vapors in the 2. Do not touch electrical switches. vicinity of this or any other appliance. 3. Extinguish any open flame. 4. Call your gas supplier immediately. WARNING Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier. NOTICE Effective 4/1/94 Underwriters Laboratories require that all gas burners firing at inputs of 2,500 MBH and under be supplied with two gas safety valves or one gas valve with proof of closure (Valve seal over travel). The photos in this manual may not depict these specific components. All U.L. listed products shipped after 4/1/94 will comply with ULL. requirements.MANUAL C888 :. x» 1 CONTENTS 4. General Product Information 13 Combustion Chamber - General 7. Servicing and Component 1 Principal of Operation 14 Combustion Chamber Data Agjustments 2. Model identification 3. Mechanical Operation of 31. General information on ternal 2. Unpacking ané Haring FGaUAlr anil kisaise Bypass Oll Nozzle Systems 2. Warranty and Spare Parts fae oron 1 Intemal Bypass Nozzle Data 3 GeneralComponent information js Ges LoveHligh-Off and Lowsightow 34. OilNozze Flow Rates 3. BumnerComponentidentiteaon 14 Gea. Fullaghtion 34 Oil Nozzle Servicing OnOfFueliAirConlrolModes 1g GI On oF 34 Oll Pump of Oil Flow Problems 4 BumnerComponentidentifeaion —1$. Gi pred Ai Low Fe Start 35 Direct Spark Giligntion Her eer pauitlighLow 18 Reduced Air Low Fre Star System ‘Adjustments uel Contral Modes 19 Oil- Low-High-Off and Low-High 35. Oil Drawar Assembly Diagrams Se nrce Low with Webster Ol! Pump 36 Gas/Oll Burner Firing Head Modulating Fuse Contol Modes 9 Qi Low-High-O1 and Lou High- Cutaway 5 Santeatuene Oeorsond Low suri 25ip O1Punp 36. Gas and Gas/Ol Gun Assembly i 1 Oll- Full Modulation Diagrams 4 Standard Buer Ratings and 39. fuser Postion Adustmentfor Gas, 37 Gas Bumer Clie Sling 7 component Data Oil or Gas/Oil Burners 38, Limting Orifice information cose iaeae 22 Gas of GasOH Bure Ful 59. Gos btn kustment Premix Adjustment 39 Pilot Spark Ignition Electrode 9. Gas Supply Piping - General 22. GasiO\I-Linkage Arrangement for ‘Adjustment Gas Supply Line Sizing Charis Full Modulation - Standard System 40 Gas Pilot Flood Test 10. Gas Traln Components Supplied — 29 Gas/Oil-Detaland Adjustments on —_4y_Flame Safeguard Control Flame for Standard UL Bumer Modulating Varicam™ Characterized Signal Values Requirements Fuel Metering System 41, CO,-0, Ratio Curves for Fuel 10 Gas Train Piping Schematics, for Standard UL Burner Requirements, 11 Oil Supply Piping - General 4, StartUp, All Fuel 23 AllFuels - General Start Up Procedures 42 Trouble Shooting Suggestions 23 Information on Fuel/Air Modes of ils and Gases, 8. Maintenance 11 Oil Purnp Suction Capacity and Ce eee eee 44 General Filter Selection information ee 45 Periodic Check List 12. Oil Line Sizing Charts 24 Burner Start Up and Service Test 9. Burner Start Up Information 12. Oil Pump Detal Equipment Required and Test Data 13. Multiple Burner System Ol Piping Schematic 13. Combustion Ar Requirements 5. Gas Star Up 25 General Gas Start Up Procedure 47 Control Settings 6. OllStantUp 13. Burner Mounting - General 28 General Oil Start Up Procedure 46 Combustion Analysis 51 10, Gasand Oll Burner Owner Operating Instructions GENERAL PRODUCT INFORMATION Principal of Operation Power Flame Type C Burners Incorporate the principles of pressure alomization for oll and mutiple orice, ventur ‘operation for gas. The total package utlizes the forced afl, lame retention concept. The Type C burner is listed and jabeled by Underwriters Laboraioras, Inc. Capacities, ‘when fied at 0.2" w.c. positive combustion chamber pressure, range rom 30 136.4 GPH of commercial grade #2 fuel oll andlor 98 lo 19,100 CFH of natural gas. Ak for Combustion is furnished by an integrally mounted combus- tion air fan. The Powter Flame packaged combustion system can be operated under positive or negative fumace pressures with clean, efficient combustion In a wide range ff combustion chamber condilans. (Consult page & for Appropriata ratings) Power Flame Type C Burners are designed to produce greater lame turbulence and reduce flame size. AS a Fesul, they require less. combustion volume for complete combustion and can be easily fred under positive furnace pressure. Forced draft pressurized operation requires stacks of smeller diameter and height The Power Flame C Burner is a totally packaged and factory tested combustion system offering single unit responsibilly, The package Incorporates accurate control fof the fuelairrallo throughout the fring renge with the resultant controled flame pattems and clean combustion for maximum efficiency, Combustion alr flow is conirolled by a multiiouvered damper assembly. The combustion alr Is supplied by an integral motorcriven blower, which discharges into the bumer blast lube assembly. High turbulence flove is controlled by means of an adjusiable fan difuser system. Various system made operations are oblained by applying appropriate control valves and fuels actuators. Unis are capable of operating in modes consistent with specie demand requirements, from fired or on-of through ‘ull modulation, ‘The airfuel rato is established at the time of start-up and proven with combustion test equipment to provide the Fowest practical oxygen with a clean flame:A Flame-Safequard Programmer, avaiable in various control sequences, programs the fing cycle. The ‘operating cycle Is sequenced to ensure normal and safe conditions Before fuel can be introduced into the combus- lion area, The camplee fing cycle is supervised {0 ‘ensure thal ignition of main flame Is properly established ‘and maintained, Both direct spark and gas pilot ignition syslems are available. Flame monitoring Is provided by ‘optical scanner ofthe cesium oxide, ead sulfide, cadmium sulfide or ultraviolet types. ‘The limit circuit Includes the operating limit control to maintain Set operating pressure or temperature, as well as 2 high limit contol to guard against excessive pressure or temperature. Low watar and other simlar safty controls ‘can be Interlocked Into the bumer control system 10 Tt specific Job and/or code requirements ‘The control cult is normally 120 volts. A contro crcutt, ‘ransformer may be furnished to provide the 120 volt contro circul for polyphase motor applications. The contro cicut is frequently interlocked with the polyphase ‘olor circut to shut dawn the burner in the event ofan Interruption of the motor current Power Flame Type © bumers are capable of fring single or ‘mult-uel appicaions. (See model selection, page 6, Table 2) MODEL IDENTIFICATION The numerical suffix after the leler C denotes the bumer frame size. The leler R inserted immediately after the letler C denotes an inverted blower configuration. The alphabetical designation immediately following the frame size indicates the fuels to be used: Gis gas only ©, oil anly; and GO, combination gasiol The two numbers following the fuel designation, in all {gas and gasioll listings, denote the standard gas train Size. (Selected components may be different pipe sizes than the nominal train size coded.) 10 gas vain 12 Vie gas Wain 15 _T" gas train gas ran 2h gas Wain For mull-uel burners, uel changeover may be provided by automatic contol, influenced by outside emperature or manual suitching, Interlocking relays and timers ensure sale changeover of fuels by means ‘fa timed inferuption of fring, lng enough to cause 2 complete recycle of the programmer. ‘The prewired Control Panel is mounted and wired as an integral part of the bumer in accordance wilh Fecommendations of Undervrters Laboratories, Inc. and National Electical Code. Components are wired to rhumbered terminal strips. Panels and burers are factory fre tested before shipment. Comprehensive wiring and gas andlor oll piping dlagrams are furnished ‘ult each burner In accordance with Individual job or application requirements. Wall mounted or free-standing Control panels are also available, Power Flame C burners are available with control systems fo comply with the requirements of Factory Mutual, Industral Risk Insurers and any special state, ‘municipal, local and utlty company codes, including New York City epartmert of Buildings (MEA), NYC Department of Environmental Protection, Commonwealth of Massachusells, State of Conneciicul Fire Marshall, Iinois School Code and others. Fuel (gastoi) ‘ype Standard gas tran size (1°) C1-GO-12 Frame size (see capacity ratings) Any alphabelical sux (Such as A, B,C, Sor V, etc) t0 ‘he fuel designation denotes special product coding (consul factory), See page 6 Standard Burner Ratings and Component Data for further information, UNPACKING AND HANDLING Type C Power Flame bumers are usually shipped as a Unit with an integrally mounted, prewired control panel ‘Avemote fuel of pumpset is shipped separately on the larger size oll and olligas units. Gas train components ‘may be mounted on the burner ar shipped loose for field mounting Uncrate bumer carefully and check all parts received against the computer generated Bumer Spectication Sheeis supplied by Power Flame. Components not mounted on the bumer (shipped loose) are designated vith an Lon the sheets. Claims of shortage or damage ‘must be immadiately filed with the carrier, WARRANTY AND SPARE PARTS INFORMATION Power Flame offers a 15 month Limited Warranty on all components from the date of shipment. See page §1 for details “The Oumers Information envelope packed with the burner contains a Warranty Reglstation Card. The Warranty Registration Card is also a request form for a computer generated Spare Paris List. An on-hand supply of spare pans Is highly recommended in case of emergency shutdown. The pre-addressed. pos e pad Warranty Registration Card should be completed and. returned to Power Flame. In the event that the Warranty Registration Card 's lost, please contact Power Flame's Customer Service Department in Parsons, Kansas. All ‘communications withthe factory will be handled more ficiently f the burner Is identified by the burner model, Serial and Invoice numbers. This information Is Stamped into the bumer nameplate that is atlached 10 the integral contra panel (or to the burner, when remote control panels are supplied)ca ‘The contenis ofthis manual are general in nature, ‘The computer generated Burner Specication Sheets due to the wide variety of equipment specications, shipped with the burner represent the as bull version of, insurance requirements and state, local and other your speci Power Flame combustion system. Part codes, ‘Rumibers and component descrictions wall match those ‘components supplied. A duplicate set of Bumer Specication Sheets is avalable through Power Flame’s Customer Service Depariment, Figure 1 ‘Burner Component identification ‘Typical for Model CR-GO with On-Off Fuel/Air Control Modes of Operation.” Blower Motor Blast Tube Air Inlet Housing A elt Camper Manual Adjustment Air Flow Switch Drawer Assembly Cover Plate Drawer Assembly Adjustment ‘Nr Difuser Flame Retention Ring Gas Pilat Regulator 11. Gas Pilot Solenoid Valve 12. Gas Pilot Test Tee 13. Gas Pilot Assembly 14. Gas Pllt ignition Transformer 18. Flame Scanner (Detector) 16, Oriice Tee with Gauge Test Port 17. Automatic Gas Valve 18. Leakage Test Cock 19. Oil Pump. 20. Gil Solenoid Valve 21. Control Panel 22. On-Off Swaich 23, Fuel Selector Switch 24, Hinged (Total Access) Top Section 25. Light and Switch Cicull Board 26, Removable Total Access Door 27. Optional Board for Sequence Indicator Lights “The components and arangements shown fae typlca for a Magel C&-GO comoinaton {es/ol burner. Gas ony or oll only units wil Rave sklar components relating to thee pectic ful In some cases, tho Type of ompanants andior ther aangement may ‘ary fom this depicion. For specs on your system, refer tothe technical iforma- tion supeiad with the burne.ca evra Figure 2 Burner Component Identification ‘Typical for Model C-GO with Low-High-Off or Low-High-Low Fuel/Alr Control Modes of Operation.* 1. Blower Motor >) Best tube @ 3. Air Infet Housing 4. Air Flow Svateh 5. Ar Difuser 6. Flame Retention Ring 7. Gas Pilot Regulator 8. Gas Pilot Solenoid Valve 9, Gas Pilol Test Tee 10. Gas Pilot Assembly 11. Gas Pilot Igntion transformer 12. Flame Seamer (Detector) 13. Orifce Tee With Gauge Test Port 14. Motorized Gas Vale (Low-High-OfT oF Low-High-Low) 18. Al Damper Brive Linkage Assembly 16 Leakage Test Cock 7. Gas Premix Adjusiment (Optional Feature) 18. Oil Pump 19. Hydraulic Demper Actuator 20. Oil Nozzle 21. Low-High Off or Low-High-Low Oil Control Train 22, Control Panel 23. Hinged (Total Access) Top Section 24. Removable Total Access Door 25. Test Port “The components and arrangements shown typ for 2 Model C combination ‘gasod burner. Gas only ora ony Units ul ave similar componente Felting to thek spect fel. in some cases, the Iype of components andor melt ‘rangement may vay trom this depiction, af specties on your system, refer to the technical information suppled wih the burner Figure 2 Burner Component Identification Typical for Model C-GO with Modulating FueV/Air Control Modes of Operation.* Blower Motor Blast Tube Air Inlet Housing Ai Inlet Damper Cross Connecting Linkage Ar Flow Switen Flame View Port Drawer Assembly Cover Plate Drawer Assembly Adjustment AN Difuser Flame Retention Ring Gas Pilot Regulator Gas Pilot Solenoid Valve Gas Plot Test Too Gas Pilot Assembly Gas Pilot Ignition Transfocmer Flame Scanner (Detector) 17. Modulating Buterfy Gas Valve 18. Modulating Drive Motor 19. Jack Shaft and Drive Linkage 20. Gas Pressure Gauge Test Port 21. Gas Premix Adjustment (Optional Feature)22 23, 24 28, 26. 21, 28, ‘oll Pump ll Nozzle ‘Modulating Ol Valve Oil Nozzle Bypass Pressure Test Tee Nozzle Return Line Check Valve Control Panel On-Off Switch 29. Fuel Selector Switch 30. Hinged (Total Access) Top Section 31. Light and Switch Circut Boara 32. Removable Tolal Access Door 33, Motorized Gas Valve 34, Test Port 35. Optional Board for Sequence Indicator Lights Note: See page 21, Figure 25 for depiction of characterized fuer contol systern “The camponents and arrangements shown are typical for Model 60 combination gasill burner. Gas only (C-6) or ail ‘nly (€-0} units wil ave simila”componenis relating to Thee specie ful Standard Burner Dimensional Data Figure 4 ant In some cases, he type of companents andlor thelr ‘arrangement may vary fom ths depiction For spaces on ‘your systom, reer ta th technical rvormaion supgled wth the burner Model C Configuration Ye 0. holes Note: ‘ad i 0-H" fr sizeof opening in bot front plate * Dimension may be reduced by 100" by ‘moving panel fo appropriate aerate ecaton Figure 5 ‘Model GR Configuration Nore: ‘eld i oH fr sizeof opening in ‘ler front plate * Dimension may be reduced by 105)" ay ‘moving pane fo appropriate aerate ‘ocatlon Sanda DSS Da ee wane An PP Seo ae ection eg Te Sear ar Sh etek at pepe gt ti aoe eg «tis dimension may be increased. Consul factory. Note: Dimensions snown are standard, but may vary a6 10 feomponent changes, ele aS6. ovat Table 2 ‘Slandard Burner Ratings and Component Data Power Flame Cariied Capaciy 0.2° W.C. Poslive Pressure (D) Sipe Sande Sead GS? MBTUN Nonfat Ga Sida Sorar Purp Sacon Canam Meas ane, Gone Mavran NaalGs ok) rosie Gatian — Ger ran an 8 soci uate Wsinon | Ties Regret “Sels' vance | olttesaehang = HS ee es eer i wes in Schon Sy Sars int reap" AR Gee, del CGO (Conbinaton GeO e101 Ws a ee C1-GO-12 UV h 97 1360 32.3 S314 Te 190) 8 19(4) C2-GO-15 uv He 367. 2200 523 5214 Te Fo(K) a 7O(K) 3.60208 UV 141800600 62.60.2081 Wa sonata ry 63.60.90 UV 3 a0 ano as 68.6095 UY 5a ig00 28 tos e—t08 G02 WS seas ee 646025 UV 8 as B00 00a a 4:60.89 UV S600 ee 65.60.89 UY 7980500500 F998 WA 80 €5.60.308WV 7k 8 ost 9500 tr 8 a NIA 66.60.19. WV 10 0 eats 028 WIA 80 67.6010 UV 1s sata 17,000 aoc 40280 Wat 8 C1030 WV 30 a6 77-700aa 8 —a0.380 Wika 68 6:60.19 UY 18 tak —,300 454050280 NK 8 Model (Gas) a ee TST : z cia We tage 5 2.65 Wea : 5 C2620 WW ast 0a : 2.6208 WW} aos a : 63.620 Wp a0 one : : 68.625 WW tg ig ——is 63.6268 WW ease i 46.95 W800 8a : C6630 WW 8 eno goa 8.680 WW tos 9500 T9928 : z 5.6:308 WW Phe 0500 25007820 : : cee0 70 Tos 30096528 Es 5 e760 5 17.000" 4040 40.9808 5 ae C16 308 Wa 9) 700.0 A : : [oe a oe Model 60 (3) choG) een 5 era ES _ ay CzONS] 66k te 3 Tak) FOUR 2088) eq ha Ee es — 30 a a ee ce a ca08 ws ars Ee ase as (7 Sa ee ee ee ae te 5.0 Ww easy = Nik 480 5:08 wh z Wik 42850 a Wy 10 ors S WA 280 er Uys ata z os (7 a = a 0 re a NK 268 A. Soper tuter modelnumbertamaton 8. Thefarosensr sewn Uta Vee e CC (Ca Cal). ome ‘ies suchas ead sudo nepha r seletcoelyw ‘Sporeabrsercedes separate punpls supe WP may boretucod For posto pressire Bpebcstngan 1 eurer tr htsfapump gon &GPHorsnoOEM ‘oles 3 12H robe ardonrdzsafnatereautezonotandgastttares 0. Capactosttosar based ond WC. postin esse. Dertcapactes| ‘Spuronraleysforeaen 0c caren nro wt, {reel for C28 and Cs G0) 08, charred fer 20 HP at 1. ‘WC Aespoctes sadn 0 aon Dee psc foreach seit rai shtick bumet operating at mantra int aunty gesvaies oused, 200) 208g C+ OFDM ossaeot 2 (19) eperadan wins opel 283 ego. ode numbers al bays standard UL Ete asian ses to cvebienth UL ingulsngs. The cualan semsy ay capeeg oneal ges upp pressressvati Sucsonino ander mes edo prove hose sco capac, ‘Donato susie or capactesbasason burton aes, ‘Seepage tebe aman 1 C20wuteesueptes uma Uvsenser tng abe 20H (anessspoctod eee).cr ret 4. thastanardpump nema upp 19 GP fr Or Moaing Tesi pump noma supp 40 GE ke Low HgvOtand [esd Giver Pog aw fre St Low igh tans Law ow eat igh Lo, 7OGPHer Or end medustng oeraton, Opel ‘pum Opal purest bist Seinen els, pores resealableferLowrrigr-ofanuon-hapdom iene ‘Supe sehigh as TO Resets ermaten ope Bust Ens nghas 10 Gt. Relrtoarnatn shepad Nhe arnt ‘ecdar consti yor spectior ‘Sderconsthetacarytor specks, Control Panel Information Figure 6 Total Access Control Panel (Patented) Featuring Alpha System™ Circuit Board vith Light & Switch Board for a Combination Gas/Oll Modulating Bumer 1. Power On indicator 8. Automatic Mode Indicator 14. Main Circuit Board 19, Motor Starter 2. Control Switch 9. Auilary Light Crcult Board 15. Flame Safeguard Conrol 20. Light & Switch Circuit 3. Fuel Changeover Switch Indicators 16. Slepdown Control Voltage“ Board 4 Gas On Indicator 10. Demand indicator Transformer 21. Ausliary Light Board 5. Oil On Indicator 11. Main Fuel Indicator 17. DIN Rail Mounted Terminal" Indicators &. Manual Potentiometer 12. FSG Alarm Indicator Stlps 22. Motor Overloads, 7. ManuakAulo Select Switch 13. Customer Selected Indicalor 18, Primary & Secondary Fuses Figure 64 ‘Alpha System™ Typical Layout Drawing @O@ © @O© G Replaceable Fuses (C1 Main) Hot 115 Volt Main Power Connection” Main Circult Board Flame Safeguard Base On Cecult Board Light & Swvich Board Connection “Terminal Strip for Field Connection Chassis Pate Motor Starter Replaceable Relays- MY2-AC10/120S Only (U1 Fused) Aunty Power Connection (Factory Use Only) (U2) Neural 115 Vou ‘Grounding Lug ©O * L1 Main 118 volt hot incoming power terminalis located atthe top of the circuit board, L2 Neutral 115 volt power {terminalis located on the lower set of terminals at the bottom of the main ckcult board. The L1 Fuses terminal located on the loner set of terminals s fo factory use only and should not be used for Incoming power connections.Figure 6B ‘Alpha System™ Circult Board Typical Elecvical Schematic with Light & Switch Circuit Board yO @ D®@ OMOOE DIO MEO * L1 Main 115 volt hot incoming power terminal i located at the top of the circuit board. L2 Neutral 115 volt power terminal Is located on the lower Set of terminals at the bottom of the main ccult board. The L1 Fused terminal (nok shown) located fn the lower Set of terminals Is for factory use and should not be used for incoming power connections Figure 6C @ QB 1. Main Clcult Board 2 (L1 Main) Hot 118 Volt Power Connection* (12) Neutral 118 Vol Wiring Connection* Control Cicult Fuse Primary Fuses, Motor Starter Step-Down Transformer Light & Switch Circuit Board ‘ually Light Board Connection (typical) 410. Wing Terminal Strip Identincation 11. Gas Ignition Transformer 12. Operating Valve Connections 18, Modulation Motor Connections 14, Limit Device Connections (Typical) 15, Running Inteock Connections 16, Motor Starter Coll 17. Operating Control Connection 18. Flame Detector Connection 19. Alarm Buzzer or Bell Total Access Control Panel (Patented) For Combination Gas/Oil Modulation Burners ‘This Total Access Control Panel is typical in general construction and configuration forthe fuel and mode of operation indicated. Each burner is shipped with a wiring diagram, as well as specific documentation on specific ppanel components. Side view of removable front and top 41. Control Switch 2. Fuel Changeover Switch 3. Manual Potentiometer 4. Manual-Auto Select, Sitch Power On Indleator Main Fuel indicator ‘Auxiliary Functions ‘Motor Starter Motor Overioads 10 1. 2 ppanel doors. To remove front panel door, place unlatched door in closed position and lit it up. Far total access to components mounted In the top panel, remove the four holding screws and rotate the top panel upward, around the hinge located at the lop rear of the panel Box. ‘Stepdown Control Voltage Transtormes DIN Rall Mounted Terminal Strips Primary & Secondary Fuses 13. Flame Safeguard ControlFigure 7 ‘The Director® Annunciation System The Director® Annuncalion System Mounted on removable Total Access front panel door, complete with {quick disconnect electrical connection. The Director can 'be removed from the panel box (See above) and kept in ‘operating mode by using the extended length umbilical ‘cord betwoen the Director and panel box connections. ‘Annunciation Legend for Gas/Ol Burner with Low-High Low Operating Mode Power On Limit Clout Closed Flame Fallure (Flame Safeguard Lockout) ‘Main Gas Valve - Low Position ‘Main Gas Valve - High Poston Main Oil Valve High Fire Oil System High Fie Air System INSTALLATION The installer should contact the local gas ullity relative to available supply pressures, limitations on allowable pressures in the bulding, general piping requirements f’nd applicable codes, resictions and regulaions, ‘Considerations of these types, as well as writen permits and other stale, cty and lacal codes, should be siscussed with and approved by the appropriate governing bodies. GAS SUPPLY PIPING Gas piping should be sized to provide required pressure al the burner train inlet manual shutoff cock, when operating at the maximum desired fuel input Allgas piping should be appropriataly pressure tested to tensure leak Irea operation, Its recommended that a dit pocket or trap be piped into the gas supply system Just ‘ahead of the bumer train inlet manual shutoff cock. When testing with pressures higher than the maximum pressure ratings of the gas train components, be sure to Isolate these components and test their piping for gas leaks with correct pressures only. On some bumers, the Table 3 maximum main gas train andlor pilot gas train compo- nents pressure is ‘fs psig. (14° WC) Refer to Table 3 for information ralating to the slzing of {gas supply plping. Those char's are based on the {oneral flow characteristics of commercially produced Black wrought iron pipe. iin doubt regarding low capabilities of a chosen line size, the nex! largest size Is recommended. Refer to page 10, Figures 8 and 9 for typical gas pining schematics fo meet U.L. requirements in the C burner fring ranges. Table 3A Capaclty of Pipe - Natural Gas (CFH) Correction Factors With Preaaie Ofop of 0.3" ne. and Specie Gravy of 0.40, ipo Length Pipe Sw inches 05) ‘Specie Gravy Specite Drop Woot EF [Other Than 0.60_ Than 0.3 520 160030504900 8500 47500. | Specific Matiplier” Pressure Mulipie™ 20360 “110071003300. 5900 12000 | Gravity Drop 30288 9016502700. 4700-9700_|_050 1.40 a7 08 40248 760450 2300 #100 _€300.|040 4.00 02 ats 50 218 ‘7012107000. 3600_ 7400 |0.70 092603 1.00 60195 410, 115018503250 6800 | 080 O67 04 116 70-180 56010501700 30006200 | 090 81708 142 60470 30990 1600. 2900800 | 1.00 0.778 60 90160, 490930 150026005400. | Propane Ar 83 00150305 4408701402500 sto |_ 1.100.740 258 125130295 078012502200 4500 Fropane 316 750120250 3807101302000 #10 | 1850.62 3.65 1750225350680 10501850800 ‘Butane ‘AAT 7200/00 210320610980 1700-3500 |_200 0847 58 Tica: Uso matin at ight for cer spaciic grales and pressure ops. co10 Table 4 Equivalent Length of Fittings in Feet Fipe Size (PS) ee 125 GE 2 Ra Be ‘Sid, Too trough Sie BE 75 90 120140 170220 ‘Sig E11 2737 AS) 65 6580 1120. wen 4216 20.) 25 80.3780 ug Cock 304055075 9a 120 160 Table § Gas Train Components Supplied for Standard U.L. Burer Requirements See Gas Flaw Schematics this gage, Fue & and 9 for adaltonal formation Fue ir Conzes Modes of Operation conor Lowniigh'ot _Lowltightow __ Modulating tain Gas Cock xu XU xu. ain Gos Presse Regu Haseue xu xu. High and Low Gas Pressure Swiches ‘OU, xu 2 xu, ‘Automatic Main Gas Valve smite x xu, ‘Auiomatic Main Gas Valve wih Proof of Closure ° x x Hain Auvary Gas Valve Seo x fg Leak Test Gas Cozk Tes x xu. Pot Cock Pressure Regulator & Solendid Valo ieee x ix Modulating Buty Valve NA WA x ‘Sige Too Orifice Assembly ees x Wa Hala andlor Pot Gas Pressure Gauge 0 o o X-Supplled as standard O-Oplional —-NA-Not avaiable (U) -Unmmourted 1. Supplied as standard on inputs of 2.500,000 BTUs. and abate, Avalable as an optlon below 200,000 BTUIy. Inputs 2. Supplied as standard on inputs of 5,000,000 BTU. and abate. Avalae as an option below 6,000,000 BTUMy Inputs * Certan bumers wil have 8 combination pressure regulator! aphragm gas vale In Feu of a separate requir and abe. Canadian oleccal and fust codes require systems that ‘ary rom the above. Cansut the factory foe specte deals Figure 8 ‘Typical Schematic Gas Piping for Type © Burner, On-Of, Low-High-Off and Low High-Low System Fe Piped Way Be oni on UL Bie re Plot ke ti ot exces 8 od as Supls ae Solenoid Pressure sn pot close syste en Beane, Mm mor © Denotes nt required below Plates oe 2500 WE, i 8 Prot of osu eto Regular a ‘required above 5,000 MBH. esstumer + NO, vr ae recuted above font ‘zoo nett ‘MLO units comply Ald Manncas —Alary pOrmies Tee" piped. Dit Leg witiCap Pressure Gas Vahe Ye Pressure Tap Extend Fear Regulator Gas Vato (ith Pressure Tap: Ney ks Pipe Sahn Nipple Tesi Cola Figure 9 ‘Typical Schematic Gas Piping for Type C Burner, Modulating System Fels Ped Way be omiied on UL ted ae 7 Ba urs xen © 020 N 95 Sun Solenoid Pressure \when prof of cose system fs eer" aie TP caer umished a (Gare © Denotes not requred below PierGes 0 Cena onto Amosphere as Prmited by Code | Presse 7 ign Gas | Regulator root of osu feature eon Sas ‘equlea shee 5,000 MSH +N. vent vate requkes above Main as 42.500 MH Shute ek Tain Gas Autry Man F kt Leg with Cap Pressure Gas Valve Gas Vato futerty Vae Exendto Hoar Reguator* (iin Pressure Tap: May | Operated by lg Ppa Bein Nipple er Tes Coed) | Modulating Moto) * On same bummer models a pus belo 2500 MBH» combinalon ress re ane mate al pds boy 20 BM 2 btn lsotautomae gas ave may be used my place ote saparale man aos ar species on our bua to he Gs Fey agreh Supal thecu OIL SUPPLY PIPING The C bumer Is designed for use with light grade ful lls + commercial standard grades #2 0r #7 11s recommended that prior fo installation all national, local and other applicable codes be reviewed to ensure total compliance Its recommended that prior to installation, NFPA-31 and all other national, state, local and other applicable codes bbe reviewed to ensure total compliance with their requirements including, but not necessary fimited to, the use of anti-syphon valve(s), of safety valve(s) (OSV), or other accepiable means to prevent siphoning ofthe oll when lank Is above burner level. Even if such devices are nol required by code, they should be considered {900d installation practice and mandatory when the tank IS above burner level Do not install manual valves in the return line between the pump and the tank unless required by a specific code. I'a manual valve is required, an automatic reliet Yalve must be installed across the manual valve to ‘ensure that oll wil bypass directly back to the tank in the event the manual valve is inadvertently let in the closed position. Use copper tubing with flare titings or iron pipe on all Installations. All unts must ultize the proper size and Table 6 type of suction ine oll ters, See this page, Table 6 for recammended Power Flame oll fits, Ifthe oll storage system has been used with fuel heavier than #2 fuel ol, the entire system shauld be thoroughly ‘leaned and flushed before siating up the new system. Utiize fusible link andlor overhead ant-siphon valves aS appropriate. IHiton pipe oll lines are used on underground tanks, swing joints utilizing nipples and elbows must be used ‘and joined together, making certain the piping connec- lions are tightened a the tank settles. Keep swing joints. In the suction and return lines as close to the lank as. possible. Underground tanks should be pitched away Irom the suction line end of the tank to prevent sedienent from accumulating al the suction line entrance. The suction line should be a minimum of 3" trom the tank bottom, Before starting up the system, all appropriate air and oll leak tests should be performed, Make certain thatthe tank atmospheric vent line Is unobstructed Reler to page 12, Figure 11 for fuel pump ol piping ‘connection information. Further Infarmalion Fealing to burner ol piping can be found In Table 6 this page, Figure 11 on page 12, and on page 13, Figure 12 Oil Pump Suction Capacity and Filler Selection Chart {GasiOi Nodel ‘il Mode ea Poner Temp ‘erate ‘Suction Capaciy Ob Fer Mage ‘Sitter oreo 7003) Tei Ful FEA cr-60.12 (G1.0 and 61.05 70(1) 75410 (Fula F8:6) 2-60-15 ‘G20 and C20AS 702) 73410 _(Fullo- FB-6) €2.60-208 ‘62.08 and ¢2.088. 40 6101-100 73410-(Fullo FB-6) €2.G0-208 (C208 and C2085 40. 7o101-100 73410-(Fullo FB-6) 3.60.20, 3.0 105; 70101100 73410 (Fulflo FB-10) c360.25 C30 105; 7o101-100 "73420 (Fillo F6-10) €3.60-258 135, Foto1-100 73420 -(Fulflo FB-10) 4:60.25 135, 7ot01-100 "73420 _(Fulflo FB-10) 64-60-30 135; 0101-100 73420 (Fuiflo FB-10) 5.60-30(6) 250 = jot0%-100 6-60-30 250 (C7-G0-30(8) 7-0) 0 TOO 8-60-30 1. The standarel pump narmally supplied Is 19 GPH for On-OF ‘oF Modulating ars 40 GPH for feed alow fre star, Cowigh-Off and Low High-Low operation. Optional pumps ara avalable which, depending on modo specified oul be as high as 70 GPH. Refer f information Shipped ‘wth tho burner andi consul te factory fr species, Lis very important fo property sie the oll suction ine andt oll filer, to provide fuel flow to the burner without exceeding 410" suction pressure (vacuum) at the oll pump suction port 73290 (#72 1° Heyward ‘th 100 mesh baskel) 70101100 2. The standard purnp normally supplied Is 40 GPH for Low High-O1 and Low-High-Low and 70 GPH for On-Off and Modulating operation, Optional pumps aro avaiable for Low:high Om and Low-tigh-Low which could be as high {98 70 GPM, Refer fo sformaion shipped withthe Burnet sna consul the faciory for spect, ‘The method to properly size copper tubing Is outlined ‘on page 12 (Figure 10). Consult Power Flame Customer Services Department for sizing assistance regarding iron pipe.ci2 Be 8 ela] » ‘Suction Capacity in G.PH. Inches of Vacuum at Fue Leet SESREESERS Total Feet of % O.D. Copper Tube #2 Fuel Oil 1. Check oll pump GPH Suction Capacity shown in Table 6, 2, Measure total tube length (horlzontal and vertical from the fend ofthe fine nthe tank to the connection atthe ofl pump. 3. Choose the appropriate graph above based on the tubing Size, Read up ram Rorizantal ine Total Feet of Copper Tube to Suction Capacity in GPH. 4. Read left tothe vertical Ine Inches of Vacuum at Fuel Unit (Gis isthe vacuurn required fo draw oll hough the length fof tubing selected) 5. If installation has lit (Lis defined 2s the vertical distance the fuel unt Is above the top of the tank) add T° of vacuum for every foot of tit, Total Feet of "3" O.D. Figure 11 Oil Pump Details The olf pumps depicted In ths section repcesent the most commonly used madals. Far models not depicte, DIRECT DRIVE OL PUMP Piping connection may fot be laenteal fo Blower moter ‘even pump. See pump feermaton plod with burners DELTA OIL PUMP DETAIL BESRRRRSEE Copper Tube #2 Fuel Ol SESRESE a8888 Toll Foot fH" 0.9. Toa Feet ofr OD, Copper Tube #2 Foal on Copper Tube #2 Fos O4 Ad he vacuum detemines tom ems 4 and 5 together tb detsrae toll hehes of Voclum oll ove 10 move one ger bing sl chart and reveals lal hes of watt, The Instructions above do not alow for any ade Teailtons gh as ho os sows Sha bends chock valves te, Sut tre vacuum vahes for Such CoMpO- rans vary by monufacuna ‘Rule of Thumb o determine tll vacuum fr sution tne Sui to nda 10% to vacuum detained om gre 0 Sactatons, tis aluays ste osc the rer Ine fem pump to tank at Ihe some sk ose selected sucton tne aesgg such as the Suntee Model J or H, refer the pump manufacturers bulletin that Is supplied with the burner WEBSTER 3450 RPM BL OWERMOTOR DRIVEN OIL PUMP. Pressure Gauge Pot (or Air Bec) Pressure Gauge Pea! ys NET Vaca Po NPT ee Hat Pot jeNPT Inet Port ie" NPT! Reta Port 4" NPT Nore Por COptonal Return Por Sener ve NPT Ly Js: lon Seow Under Cou Sera for Novela Pressure Sting = Optional nt — TENET Optnel net Cope! Retan Port ener De NBT SUNTEC TWO STEP PUMP DETAIL _ Rogue Seti fair Sotnais DeEragzeal gem dater siting (Cow Pressure) (wah Sclenald Ehorgzod) {High Pressure) J let 1 NPT Nozze Pert te NET Gauge Port : ie aT tet ve wert Easy Flow ‘At Bleed ValeC Rew Figure 12 ‘Multiple Burner System Ol Piping Schematic (Flooded Suction) Vent Fi Tee wih Plog To Tank Return Vent igrest PMD BL vacuum Breaker vacuum fo} Slandoy Egupment H rom Breaker B22) Same Shown coms Supply Pump Min co = Connection ee Rest Press Gauge wih etm tine Compound 10 Burner to Tan Snubeer gesrel Gauges Pump ‘check Vatve I am ‘shut of To Bune: Pump | Connection Sueiton COMMEELON pic sa Por Ft Upward Tonard ott Retun Ena From Detail A Tanke ‘Croustng OM Resenor (Stay Be Placed Horlzntay, Soe Dela Adattionat Combustion Air Requirements Fresh af required to support combustion, as wel as to provide adequate location ventilation, must be supplied. All types of fuel require approximately 12 cubic feet of Standard alr (sea level at 60 F") per 1000 BTUs fring rate, for theoretical pertect combustion. In actual practice, 2 certain amount of excess air Is required to ensure Complete combustion, but tis can vary substantially ‘with speclicJob conditions. Adaltonal als lost trary the boiler room through barometric dampers, daft diverters Burner Mounting - General ‘and sivilar venting devices. UIs generally accepted that ¥%, Square Inch of fee alr opening (for each gas oF oi! bummer in the room) per 1000 BTU/hr. fring rate will be adequate. Under no circumstances should a boller oom be under negative pressure, Jurisdictional authority relaing to combustion air and bol room ventlavon requirements vary widely. In ofder to make certain of compllance, review NFPA-S4 and the controling authortles should be consulted [A propery installed and adjusted burner isthe lowest cost| mainfenance insurance you can buy. Provisions should be made lo provide adequate space around the bumer and associated equipment to allow for ease of inspection, maintenance and service. ‘Observe codes for the minimum dearances to combustible materials. Provide a sultable burner front plate, consisting of a steel plate of ample thickness to suppor the weight of the bummer ‘and hold itil in alighment with the heal exchanger. The ‘tont plate must be protected rom heat using high temperature refractory on febox side (as applicable. To instal the burner, 2 circular opening must be cut in the ‘Combustion Chamber - General stool front plate. Four (4) mounting bolts must be Installed at proper locations to maich the mounting holes provided on the burner mounting flange. (See dimen- sional drawings, page 6.) The bumer mounting flange ‘must be securely attached to the front plate wit suitable {gasket or non-asbestos, high temperature rope packing to prevent any products of combustion from escaping trom the combustion chamber. The burner assembly should 'be supported at the base of the housing to prevent undue sirain on the front plate. (A mounting pedestal is furnished for this purpose) Type C bumers are furnished with a iting lug for ease of hhanaling and mounting, ‘Combustion chambers shall be provided as recommended in Chamber Dimension Charts, and should be constructed of high temperature refractories, in the form of frebrick or rammed plastic refractory, backed by suitable heat insulating materia CCerlain types of heat exchangers, such as warm aie furnaces, some hot oll heaters, wel base see! and cast lron packaged firebox boilers and Scotch marine boilers, se the cambustion chamber fo transfer heat, and therefore do not require refractory or other insulation. Win doubt, consult the eat exchanger equipment ‘manufacturer. Where boilers are of the mudsleg type, refractory should exlend 6" fo & above the bottom of mudieg. {All possible points ofa infitrtion or ex-tration must bbe Sealed. I the unitis o be fred under postive ‘combustion chamber conditions, extreme cara must be taken to ensure thal a 100% seal is maintained The Type C bumner is designed to provide all the ai equifed for complete and efficient combustion. Entry or lass of air from sources ather than the fring unit will decrease ils overall combustion and operational aciency. See page 14, Figures 13 through 16 and Table 7 for additional Information. acu Figure 12 Conventional Firebox Boller #1 Frere Insulaon kk Q Modal CR ay See Table 7 Ss oes soares tne tae Ta Petr Ua) " Figwe 14 Figure 18 J ypiel Fredo Installation ~ Gast ron Boer Packaged Frebox Bolt Nore Bend gato errs Sr ee, Sheet Metal love inte bot section of he Blast tbe na ta the pt ooy Opening Joker. Make cain : ee Ne fhe ebay Retactory Eonatced suc sto . Stow of oe < = Sony Stegbered, La eg hs ole fo he [Fu 1" Magness Block 4 | OPpeate Drecton cai 2 = 4° Caled Aggregate Aggregale Fl Washed int Loose Nasand 8 Cae vg Se - Figure 16 Scotch Marine Boilers - ‘Scolch Marine Boller Minimum Furnace Tube inside Dimensions _ 4 {BHP Min inside Dimension BHP Win inside Dimension BHP Min side Dimension 2 16 700 300 2 1 BH eractory 3 a5 350 af on™ 40 350, 400. az Fy | Rudess o 200 450 a ork 2 = OP Seton Note: The abave minimum dimensions are recommended. if baller censions ae ass, consult wth factory [Aburners se through reactry wit sleeve To alow fel removal Unie space betwoan sieve ahd bum bla! tube closed with norasbesios nghemp rope or KAO-Woo Tobie 7 Suggesied Fiebox Boer Combustion Chamber Dimensions — fs a a 2 ace emt a von oe SE na Bw crsowege Fae Tg come OE Bee hae C1-G-10, 800 6 19 25 3 J 7000 50 45 16 12 c1-0 980 7 #8 48. z= C4-0A(8) 7pis 38. 4 fal 43 ‘a 3 set ta crsomeee f(a Te cece OR Hg Rw C1-G-12, 4150 8 22 30 3 » 9000 65 60, 80. 13 c1-0 1260 9 23 33. 4 C5-0(8) 10500__75 54 st 4 aoow We 7 eS coco OR eB C2-G-15, 160013 25 38 5 30, 12500 | 89 60 90, VW C2-0A 210015 27 a2 5 6-0 14215 101.5 64 95 18 €2.G0-20, 1900.11 25 38 5 C7-GO-30(6), 1250089 60. 90 qT 020590008 4 Ean 42 Be 67-6308), (44000, 100 abt 98 Na we | eee S308, 188 1 MB cz08 | 390038388 os)’ 1800 4 ho 8 ao ee Uy Git ae ue |e os 3 Og Ceo, 1D No | ee 18 | oe £30 5250 37.5 40 68 3 cages 17500 125 aps 110, 24 Note These dimensions are lo serve as a guido only. and may be modifies proving appeeximato area Is ainained.MECHANICALOPERATION OF FUEL/AIR CONTROL MODES Figure 17 ‘Typical Gas Burner with On-Off Fuel/Air Control Mode (Model CR-G) MECHANICAL OPERATION: This system uses a combina- tion Diaphragm Gas Valve and Integral Pressure Regulator (1) to control the on-off operation of gas tothe Bigst Tube (2). A proven spark ignited gas pllot provides. Ignition forthe main flame. Gas flow contol rate is accomplished by adjustment of the main gas pressure regulator and by a Limiting Oritee (a lilting oxfice | sed when the gas flow rate - BTU input - through the {gas Wain components is higher than desied), located in the Orice Tee iting () at the inlet to the gas manifold ‘The Air Dampers (6) ate adjusted and locked in place with the Air Damper Arms (7) for a fixed fring rate. When the gas pilot has been proven by the flame detector*, the Diaphragm Gas Valve will open slonly, allowing gas to the Blest Tube. Blast Tube gas pressures are measured Figure 18 atthe '/t Plugged Gauge Test Port (6) in the Side ice Tee. Refer to page 37, Table 10 for oice sizing Information. See page 37, Figure 38 for side orifice deta [Not show inthis depiction. See page 3, Figure 1 Note 1 Component operational sequencing wil vay with the specie Flame Safeguard Control cing used. Ro‘er to tho specic Flame Safeguard Contre bulletin supple wih the burr for compete information Note 2 ‘Opsonal On/Off sysiems may be supped using a separate gas pressure reguaior and separate lopheagm oF motorized Gas ‘avo in lace othe combination regultarvave unit depicted. ‘Other components would remain as desebed ‘Typical Gas Burner with Low-High-Off or Low High-Low FusliA Conirol Mode (odelC-6) MECHANICAL OPERATION: The Low-High-Oft system Uses a Motorized Gas Valve (1) to control the Low-High Off operation of gas to the Blast Tube (2), as well as movable Alr Dampors (3) by means of the mechanical Linkage 4}. Gas law control rate is accomplished by ‘adjusiment of the Main Gas Pressure Regulator (5) and by a Limiting Orifce (when installed) located in the Side Orifice Tee iting (7) atthe inet plping to the gas manifold {proven spark Ignited gas pilot” provides ignition for the main flame. When the gas pill” has been proven by the flame dotector (scanner), the Motorized Gas Valve begins to open, allowing a controlled fuel/air mixture to the Blas! Tube fo low fee light off - and continues to open, Increasing the fuel’ flow until the high fre position has bbeen reached. Firing Head gas pressures are measured al the *° plugged Gauge Test Port (8) inthe Side Orifice Tee, Refer to page 37, Table 10 for orice sizing information, The burner operates at high fire until the system load demand is salssied, at which lime the Motorized Gas Valve closes and the Air Dampers are returned to the light off postion in preparation for the nex! operating cyclo. This epiction shows the Linkage inthe low fre start position, ‘The Low-High-Low system Is Identical to the Low-High Of system except that - the Motorized Gas Valve (1) has @Low Fire Operating Position Adjustment in adiion to the light off and high te operating postions. (See manufacturer's bulletin included with the burner) ‘An additional temperature or pressure controller is added {o the system, which a a selected preset point wil electrically ‘switch the Moterized Gas Vale and fir Dampers (3) to ether the low fre or the high fe position, as the systom load demand requires. Depending on system load conditions, the bumer can altemate indefinitely between the low and the high fre postions without shutting down. When the ‘system demand fs salad, the Motorized Gas Vel closes (formally ine burner will be In the low fre postion at this time) and the Alr Dampers are returned to the ight off position, in preparation for the noxt operating cycle. The Driver Arm (10) connected to the Motorized Gas Valve wall, Figure 19 Increase the travel ofthe Air Damper Arm (13) a the Linkage Rod ball joint (11) is moved avray fromm the Gas Valve Crank Shaft (12). The travel of the Air Damper Driven Arm will be increased as the Linkage Rod bal Joint (14) Is maved toward the Air Damper Axle Shaft (18) ‘When adjusting linkage travel, make certain that the driven arm Linkage Return Iron Weight (18) does not interfere withthe Linkage operation - and that al inkage components ae free ftom binding, * Not shou in this depo, See page 4, Figure 2. Nate 1 ‘Camponent operational sequencing wil vary wth the specie Flame Safeguard Contol being used. Refer to tne specie Flame Ssfeguard Conta bulletin supped hath the Bure! or ‘complet infomation ‘Typical Gas Burner with Full Modulation Fuel/Air Control Mode (Model C-G) MECHANICAL OPERATION: This Full Modulation system ses a Diaphragm (1) or Motorized Gas Valves to ensure ‘opening and postive closure ofthe gas source tothe Blast Tube (2). A Modulating Motor (3} controls the postioning of 2 Modulating Bulterly Gas Valve (é) and movable Alc Dampers (5) through Mechanical Linkage (6). The gas flow Control rate fs accomplished through adjustment of the ‘Main Gas Pressure Regulator (7) and the Butterly Valve. A proven spark ignited gas pllot™ provides Ignition for the ‘main flame. When the gas pilot has been proven by the flame detector, the Diaphragm or Motorized Gas Valve opens and allows gas at @ rate controlled by the Buttery Valve to go tothe Blast Tube for main flame low relight of ‘After a short period of time at the low fre positon, the Modulating Motor wil drive the Butterfly Velve and the Air Dampers to the high fire postion. The burner wil stay at high fe untl the system pressure or amperature increases toa solected preset point, a which time 2 modulating type Controller wil drive the Modulating Motor to low fire, oF whatever fring postion between low and high fire is required to match the system load demand. The Modulating Figure 20 ‘Motor vill continual teposton the fring rate in an effort to ‘exactly match system load demand, Blast Tube gas pres sures can be taken al the "A" Plugged Test Port (8) located btwean the Buttery Valve and the gas Blast Tube. Refer the Bumer Speciation computer printout supplied with ‘he burner, for specie high fke gas pressure values. When the system pressure or temperature cutoff points reached, the Diaphragm or Motorized Gas Valve closes (normally ‘he burner wil be at the full ow fre postion at this time) and the Air Dampers wil goto the low fire ight off positon in preparation for the nex fring cycle. This depiction shows the Linkage in the low fke Ught off poston. Refer to page 22, Figure 27 for information on linkage adjustments. Aso See page 22 for information on the Varicam™ moduating characterized fuel metering systom. * ‘Not shown in tis lagram. See page 4, Figuro 3 ote 1 Component operational sequencing wil vay with spociic Flame Safeguard Gontol boing used, Refer to the spoctic Flame Satequare Conirolbuletn supplied wilh the burher Tor compete formation. ‘Typleal Oll Burner with On-Off Fuel/Alr Control Mode. Pressure Gauge paoamGugeron + By Ors Ura Span “(eS Test Port Se emote ononde. oe Sunes wihfemcisPesase jenoic Low OW Nose Royo She ‘Aomieng Ol Porps quite 3 vas fected) 5:2" Roya" ten sccw Poweoas Pressite Sach {sroieene sacs oral ae ea] a olnome” canon eh Cel Prescre Frat conponenc mci = Raistnent raiding fle = 4 Poet ae ‘Saumon et Eo Eo Leases, a Check Vaio Fol SnaotL Fostietinevawe Check ots run ened SPSlpe tC Grant Vaio (© Reed by Codey" Vahe® Piper BONOTUSE TEFLON TAPEMECHANICAL OPERATION: The On-Off system uses a single stage, high suction it Oil Purnp (2) with 2 Simplex Oil Nozzle. A direct spark al ignition sysiem is standard (on typical ol burners (a gas pilot Is standard on GassOi ‘bumers), but certain insurance company codes could Figure 21 c es Fequie 2 spark ignited gas plot* to prouide igntion forthe main oll ame. The nozzle ol ow rate is set by adjusting the Oll Pump Pressure Regulating Valve (3). Tum clock use to increase the pressure and counterclockwise to decrease the pressure Io the Nozze, Normal nozzle pressure wil be 100 to 300 PSI, Refer to page 33, Table 9 to determine speciic nozzle pressures and fring rates, Nozzle pressures are taken atthe pligged Nozze Pressure Gauge Port (6). The ol on-off flow tothe Nozze is controlled by the Oil Solenoid Valve (1). The Air Dampers (4) are adjusted and locked in place withthe Air Damper Arms (5) ‘The bumer operates atone fixed fing rate. See page 12, Figure 11-and pump manufacturer's bulletin packed with the bumer for more information. "Not shown nis depiction. See page 3, Figure 7 Noo Component operational sequencing wl vary wit he specie Eine Stra Coral bang aed Ree the apse Fame Sxequard Como! blstn sop wth te uma fox canpite Noe? “The system depiced above Is based onthe use of an ol pump manufactured by COMBU Incorporated, F your sytem uses omer {han a CONBU amp, ele to bw of ipa dagram ond i pum ‘anufacsuers bullin supplied wih te Bure: fr spectics peraning to your system ‘Typical Oil Burner with Fixed Air Low Fire Start Fuel/Ai Control Mode Taw Oi Pressure Sway; Nozze Fuse Unk Yabo (at Tank) Shiro UF Required BY Code)" Valve" Drei Sot Screw ‘aver Low Fie Pressure ‘ajestent D Fat Slt Sew ‘ver High Feo ape aa uo Ie comme serra Secale sane ee rine selecerprate Donor nero Aajustent MECHANICAL OPERATION: The fixed ai low fre start system uses a two-step, two-stage Oil Pump (2) with a ‘Simplex Oil Nozzle. A direct spark oll ignition system fs Standard on typical oll burners (a gas pilot is standard on Gas/Oll burners), but certain insurance company codes could require a spark ignted gas pilot" to provide ignition for the main al lame, The nozzle Now rate pressures are taken at the Plugged Pump Nozzle Pressure Gauge Port (). The low fre oll fow rate is set by adjusting the Oll Pump Low Pressure Regulator (8). The high fre oll aw rate Is set by adjusting the Oll Pump High Pressure Regulator (3). For both high and low fires, turn the adjustment screws clockwise fo Increase the pressure and counterclockwise ta decrease the pressure to the Nozzle. Approximate low fire pressures are 160 to 225 psig and high fire, 200 to 300 psig. Remember, you will be lighting off at full ar ‘and reduced fuel. Ralse low fre enough to obtain depend- able light off with these conditions. The Air Dampars (4) are adjusted and locked in place wit the lr Damper Arms () for Ceoract combustion values atthe high fre rate. At light of, the Main Oil Solenoid Valve (1) Is energized, allowing fst to low to the Nozzle. The normally open Low Fire Solenold Valve (7) allows a reduced amount of oll to the ‘Nozze for low fre start. When the flame ts proven by the flame detector*, the low fire solenoid valve closes, providing full high fre pressure tothe Oil Nozzle. The burner operates at the nigh fice positon until the system load demand is salistied. Refer to page 34, Table 9 for specific nozzle pressures and fring rates. See page 12, Figure 11 and the pump manufacturer's bulletin supplied With the burer for addtional Information. * Not shoun in this depiction. See page 3, gute 1 Note ‘The system depicted uses a two-step Sune ol pump. fs pump tat does not Rave te integral two-step ‘uncon has been Spectied ana Supp, i il be proved wih an N.C. nozzle Bypass oll solenoid valve and a separate adjustable ow fre rl ‘ale, Refe tothe ol piping dlagram and the of pump manu facture’ bulletin suppiled sith the bumer for the species on your sistom gNote 2 Component operational sequencing wil vary withthe speciic Flame Safeguard Contol boing used. Refar othe specie Figure 22 Flame Safeguard Conl bulletin Supplied withthe bumer for complete rformaton. ‘Typical Oil or Gas/Ol Burner with Reduced A, Low Fire Start RALFS #72 bell Orig p= Nozie Pressure q Sinplon Woze Satety OF Solenoid Valves Inlet From Tan DONOTUSE TEFLON TAPE ‘Check vawe yon} bon Fee Prose as MECHANICAL OPERATION: The RALFS system uses a two slop, two stage dual pressure Ol Pump (6, or fuel unt, wth a ‘simplex nozae. Ether a direct spark or a gas pilot ignlion ‘system may be provided for Ignition of the main ol fame. The ai darnper fs string loaded to an open poston sutable {for maximum desired capacity and proper combustion, COIL CYCLE: Alter a 30 second pre-purge Is accomplished, the direct spark ignition transformer is energized. At the ‘same time the normally dosed Cylinder Solenold Valve (8) is energized, moving the Hydraulic Cylinder (8) and ait damper to a reduced air setting (combustion air dampers ‘approx. 2h" open). Combustion airs to be sel by loosening the set screws from the damper arm that connects to the damper shaft. Set the damper opening so as to provide @ smooth and immediate ightof. The amount of combustion fir needed for this temporary setting should be minimal- just enough to prevent the unit from praducing smoke. A Smooth light off with minimal airs the objective. The Low Fire Pressure Adjustment (7) ar the light-of fuel seting should be set between 90 p.si. to 120 p.sl After the air dampers have been driven to the reduced air setting or Tight tre position the Safety Oil Solenoid Valves (3) will be energized hy the flame safe-guard igniting the low fra High Fre Of Prssire Adsment Low Fhe Ol esse Aime) J Liwossiep (oul Presse) Two Sage Fue Ut @ Normally Closed Cynder Solenold Vawe@ V satay ot Soknoid vahes ll lame or the light-off lame which is proven by flame sensor {scanne’). After approximately five seconds, the normaly closed Cylinder Solenoid Valve will be deenergized, causing the combustion air damp- rs to open to the fixed air setting for mavimum desired capacity. The return oll valve (normally open) which Is integral to the Suntec to step pump (uel unt) val now be energized, providing (ull high fire oll pressure for the oll nozzle. Al the same time, the main oll valve terminal ‘on the flame safeguard will be energized and the Safely Ol Solenoid Valves will open. The adjustment for fixed air setting or full re postion will be made with the two bottom "%-20 hex nuts - see fer #1 Combustion alr dampers should be adjusted to provide 11s to 127% CO; oF 4 to 517% O; at full input (oll high fire rate) with zero smoke. High Fite Oil Pressure (8) setting should be set to the required p.si. for high fe oll rate (See bumer specification sheet for seting). The low fire should be rechecked for light-olf pressure and performance, The gas combustion wil be inllated (after 30 seconds pre-purge period) by proof of spark Tgnited gas pilot (oy scanner) which energizes dual gas safely valves. If input for gas 's comparable fo ol input then previous air damper adjustment for oll combustion should be salistactory for gas fing,awe Figure 23 ‘Typleal Oil Bumer with Low-High-Off or Low-High-Low Fuel/Ar Control Mode Using Webster 22R Ol Pump 2 Wey oF ~ gheuaessetal GA ane torr Macampenms mete Brressure N @ damper Cytinder| + fumetsuth Renoteressre Masia eprope baton Top RimtiasOiPingaregces mens aretcotaiton on NTS eee Frbm gun ow fhe Stare pessanio tune Bite SB Setlatna | opnsnamnn Fiagc Se a ‘ig Allen Seen Donor USE TERLONTaPE Ufcer Cap Far ce ‘svn Fett Piped A esse sien z eq Suge Ts Port 2 FBT vate Susana wor 6 aud by cour Gk abe aves" Presse OF Pump sone TR al Sen ann exmoude Shut Forse ere are Check Firs Vane" oy Set scum sina Fane Pipes Hank flow tothe Nozzle. A the same Instanta potion of he of Dypasces the Nozze nvough Ihe aastanie low te requlting valve, reducing the pressure atthe Nozzle as require for low Ire rates, When the ow tre lame Is proven by the ame detector the Return Ol Solenold Valve (1) deenergied, paling fil high re pump pressute on the Nozzle. simula MECHANICAL OPERATION: This Low High-OF system uses 8 two-stage Oil Pump (2) with a Simplex Oll Nozale (see ote 1, page 20) or an intemal bypass nozzle in conjunction with Movable Arr Dampers () to provide low fre start and ‘high fre run sequence. A direct spark ol ignition system fs slandard on typical oll burners (8 gas plots standard on Gas/Oil burnets) ai fring rates up fo 45 GPH, with a spark ignited gas plot” to ignite the main oll lame abave that point. Certain insurance company codes could require the {935 pill system on lower Input sizes. Nozzle supply pressure Issel by adjusting the OI Pump Pressure Regulator (3). Tum clockwise to Increase the pressure and counter clackuise to decrease the pressure to the Nozzle Nozzle supply pressure is taken at the plugged Pump Nozzle Pressure Gauge Port (6). Nozzle suppiy pressure vil normally be approxmataly 300 PSI at both high and low fring rates. Flow rate pressure for both high and low fre Is taken at Bypass Pressure Gauge Tee (18). Low fre pressures are set by adjusting the low fre Regulating Valve {@) Turning the low fre Regulating Valve adjustment rut lockuise wil increase the pressure atthe Bypass Pressure Test Tee Gauge (hcteasing the low fre Input) and counter clockwise wll reduce the pressure al the gauge (decreasing the low fe inpul. Low fre return pressure wll normally be in 60 lo 100 PSI range and at high fe in the 180 to 225 PSI range, but both pressures wil vary according to the specic nozde being used, 25 well as job conditions. At ight of the Main Oil Solenoid Valve (1) is energized, allowing fuel to neously, the Three-Way Solenoid Valve (10) is eneraized, allowing o into the Hyckaulc Cynder () which mechanically ‘hives the ir Damper Arm (13) to te high fire postion. The burner operates at full high fire until the system demand is salisjied, Refer to page 31, Table 8 or page 34, Table 9 to determine nozzle return flow pressure and flow rates, This Sepicton shows the Ar Dampers and Hydraukc Cylinder atthe low fie ight of postion The Low-High-Low system Is identical to the Low-High-Oft system, except that an adlitonal pressure or temperature ‘controle is added to the system, which at a selected preset point wil electrically switch the butner to either the high or low fre positon. When the burner is running at high fee and the Controller calls for low fre, the normally closed Oil Solenoid Return Valve (7) (closed at high ire) is energized, reducing nozae pressure to the low fre rate, Smutlaneousty, the Three- Way Soleno Valve (10) is de-energize, allowing ol to fow ‘out of he Hydraulic Cylinder (@) back fo the Pump and driving tne A Dampers (4 tothe low fre poston. Respanding to load Conditions, the burner can alternate indefintey between the Jow and high re postions without shuting dawn. When system fad demand is Saisie, all uel valves are de-energized and the Air Dampers are placed in the ight of postion in prepara- tion for the next fring cycle. The opening distance of the Air Dampers is controlled by positioning the Ar Dampor Dive Arm (13) relate tothe Acom Nut (14) mounied on tho end of the Hydraullc Cylinder plsion rod, The maximum travel swith the Damper Drive Arm postioned tobe in contact wth the hydraulic ‘llcyinder Acorn Nut at allimas. i less travels dested, set the ‘Ai Damper Drive Arm to alow a gap between ft and the Acorn Nut, (Depending on Air Damper postioning, it may be ‘necessay fo loosen Is set serews to attain proper Ar Damper ‘opening distance.) The wider the gap (wen the burner f of). the less the overall travel when going to the high fite postion ‘When setting the Drive Arn postion retative to the Acoen Nut, make certain thal the Air Dampers travel is correc for proper ‘combustion at all fring postions and that there is no binding ‘ofthe Linkage or Dampers. Make certain the cast iron Linkage Return Weight (6) is Secure on its Air Damper Arm (17). * Not shown inthis depiction. See page 4, Figure 2 Note 1 ‘The system depicted in Figure 23 uses a Webster Model 22R oll pump. I'your system Uses's Suntec H model pump, the sequenceof operation and the cil components would be Kenta tothe Webster 228 system, Fr adotonalesommation on your spece system reer 0 the ol pping disgrar an he ot pump ‘manufacturers bulletin supple wih tre burner. Figure 24 Note 2 Component operational sequenelng vl vary withthe specie Flame Safeguard Contral belng used, Refer to the specific Flame Safeguard Conia buletn supplied vith the burner for complete information. ‘Typical Oll Burner with Low-High-Off or Low-High-Low FueV/Air Control Mode Using a Two-Step Oil Pump (Model C-O) Sen ve csmsome 7” BOTttssrets srbmomee@ whe _@vanve: cyinder [OHNE OS ennetamcaae : cree cepa @orsosres [1.0 tow Fre soa ment ee = SHO a cpmersmeite Cc Ba [ee Esmee Goines al gon Beacon Switch “04 pump @—l3"5 Ear? | Screwdriver Stepp pessuetoBumer Pump pel iene” Saeheecenmae Pressure Gauge Test Fort @— ho] Sante musthat pe Tourer | SED RES Atusinent Donor Use rerLon Tare a = inet F fey es het abe Fo Tabieunk ve check fats, Pie Stl ov mates 0 ony it pe MECHANICAL OPERATION: This Low-High-Off system uses a Two-Step Oil Pump with a Simplex Oil Nozzle (14) In conjunction with movable Air Dampers (4) to provide 2 low fre stat and a high fre run sequence. A direct spark fl gation system ts standard on typical Ol burners (a gas plo is standard on Gas/Ol burners), but cerlan insurance Company codes could require a spark ignited gas pilol* to provide ignition for the main ol fame, Nozale Now rate pressure is taken at the "4" Plugged Pump Pressure Gauge Por (6). The low fre oll rae is sot by adjusting the il Pump Low Pressure Regulator (8). The high fre oil flow rate is set by adjusting the Oil Pump High Pressure Regulator (3). For both high and low fres tur the aduusiment screws clockaise to Increase the pressure and ‘counterclockwise to decrease the pressure to the Nozzle. Approximate low fre oll pressures are 100 to 125 psig land high fire, 200 to 300 psig. Both settings wll vary ‘depending upon the specic nozzle size selected and job conaitions. See pages 30-83, Tables 8 & 9 for specie nozzle pressures and flow rates. At light off the Main Olt Solenoid Valves (1) are energized, allowing fuel to the Nozzle. A normally open pump mounted Oil Solenoid Valve (7) allows a conitolled flow of oll o the Nozzle In accordance wilh the pressure setting of the pump low fre adjustment, When the low fie flame is proven by the flame detector, the purnp mounied, aormaly open Solenoid Valve is energzed (closes), puting ful igh fra pump prossure on the nozze. Simuitsncously the TThrdo Way Solenoid Vaive (10) Is energized, allowing into tho Hycraule O1 Cyinder (9) which mechanical ‘hives the AtDamper Arm (13) tothe high fre open poslion, The bumer operates a il high fre ul the Siem demand is salised. This depen shows the Al Dampers and the Hyaraule Cynder atthe low fee ight cit poston, The Low High-Low systoms ae idenicalt the Low High Of system. excep het an adciional emperstue or ‘ross contr s added tothe system, Ata selected preset point, iil elocticaly switch the Of Vales ana Jie Damper componens fo place the fring rat ener n {he low or the high fe run poston. When the burner is ‘Unig thigh fee andthe controle cats for tw fe, the noxmaly open pump mourled Solenos Vaie (0) (hich IS dosed at high fe) Is desnerqized (opens), ducing nozzle presse to the low re rate, Simultaneously, the Trreeiay Solenoid Vale (1) devenergzed ailing Oto ow out ofthe Hysaue Cynder back to the Pump {) ane ering tne Ar Dampers (3 othe low re peston Depending on load condons he burner can atemato Indesit between the fow and the high fe postions without shuting down. When system demand said uel vales ste de energized and the A Dampers are placed inthe igh of postion forthe nex stat up. The bi Daraper poston fof fee run an ight off postion se one and ine sare in hs system. The opening stance ofthe fir Dampers i conrad by postoning the Ale Damper Deve Arm (13) relative to the Acorn Nut (16) mounted on the end of the Hydraulic Cylinder (9) ston rod. The matimum travels uth he Damper Orve bern postioned to ben contact with the hydraulic oll Ginger Acorn Nota al bes. ss Wavel sds, set the Alr Damper Drive Aro slow a gap Beten f and the Acam Nur (Depending en A Damper postoning, may be necessary loosen fs Se sre 0 alan proper Ihr Damper opering dstanco) The wider the gap thon the bumer of), he less the oveal aval whan golng totigh fre postion. When sting te Drive Arm poson restive to the Acorn Nut make cari that ho A Damper travels coroc fr groper combustion at a fing postionsand that there is no binding ofthe Linkage or Dampers. Make ‘certain the cast ron Linkage Return Weight (15) s secure on its Linkage Arm (17) * Not shown in this depicton, Sev page 4, Flgure 2 tet [Component operational soquencig wa vary wih the spocc Flame ‘Safeguard Cantal belng sed. Rear tote specc Fare Sofeguard CCanol Buen supplies with the bunor fr completo formation, Figure 28 ‘Typical OW Burner with Full Modulation Fual/Ai Control (Model C-O) Ret Pressure Tap eheterng vate ® * ayotervens Spe a Tow check Va shone Pressure “+ Burrs Rens esse Tee Shieh Prassura@ Pemeertet Rontagetnonpercates Quel To oa Bae ‘ion Sczow For 08 Now, owt Peeaoe Su Nome i. Preasire Adusiment Under Donor use reFLonTAeE t 55. se Deae Fe Ped rp hzese tre caencon a Breccnowieerauraseager™ Ol Pump @—]NW/|nttoe fi et ComectonioNoai ap EEA Piunrs | Fisbleune C1 Shuto check vave canon Vane rmeausd Vato" (at Tan" eecreoeneroemo weg an jboss an op han ao a Spe peseriotunerPorpmstct [check Vane a ‘oon SESIperNPACade. ee MECHANICAL OPERATION: The Full Modulation system uses a two-stage Oil Pump @) wih an intemal bypass typo Oil Nozzle (See page 20, nate 1). A Modulating Motor (2) controls the positioning ofthe Ai Dampers (6) and tho Modulating Oil Valve (5) in the nozzle return fino trough mechanical linkage. A airact spark oll ignition system i Standard on typical ol bumers (a gas pt fs standard on Gas/Olt burners) at fring rates up to 45 GPH, with a spark ignited gas plot 10 lg the mai of fame above tat pot. Gerain insurance company codes could requlre the gas pilot system on lover input sizes. At main fame ight of tha hormaly closed Ol Valve (7) Is enargiaed, along ol to fv to the Nozzle. The Modulating Ol Valve Is adjusted fo allow 2 contllad amount of ol o bypass the Nozze, which keeps the pressure reduced tothe nozzle for low freight af Nozze oll supply pressure Is sot by adjusting the Od Pump pressure regulator (7). Tum clockwtse to inctease the pressure and ‘ounler-ioclise lo decrease the pressure fo te nozae. The low fre nozzle pressures should be taken al the plugged Oi Pump Gauge Pot (@) and should be approximately 300 PSI wih pressure atthe Nozde Bypass Gauge Port (9) from 60 to 100 PSI, these pressures varying with nozzle size and Job conditions. & typical lw fre al ow setting onthe Modulating Oil Valve would be number 7, but wil vary with Job conditions. Ater a bret period of time fr the low fre flame to stablize, the Modulating Moto wl dive the FuevAr Linkage (10) to the high fie position. At this polnt the Alr Dampers wil be full open (or as required for good combustion) and the Modulating Oil Valve will be at the ‘closed position and the nozzle bypass line willbe fully closed, puting ull oil pressure to the Nozzle. The Oil Pump Pressure Gauge Port pressure reading will show ‘approximately 300 PSI and pressures at the bypass pressure gauge pot will be 180 to 225 PSI, afhough this will vary with the specific nozzle size being used. Refer to page 34, Table 9 to determine speciic nozzle pressures and fring rates. A modulating temperature or pressure Controller wil now modulate the fring rate to match the load demand of the system, while maintaining proper fuelair ratios. Prior to reaching the system pressure or temperature operating control cut off point, the burner should be at or near the low fire operating position. At the end ofthe fring cyele, the normally closed Oll Valve willbe de-energized and the Madulating Motor will postion the Alr Dampers and Modulating Valve to the low fie postion, ready for the next start up sequence. This depiction shows the Linkage in the low fe light of postion. ‘See page 22, Figur 27 for kage adjustment information. ‘Aso see page 22, Figure 28 for Information on the Varicam™ modulating characterized fuol metering system, * Not shown inthis depiction Soe page 4, Figure 3 Note 1 ‘Some modulang Low High-Of and Low-High Low burners wil be supped with simp, rather than intemal Bypass (ype, ol rales The mechanealopetalion othe senplex nozale Sysiom [Sesser te samo as th ema aypass sysiom «excep ha law tel Presaures should be seta 100 to 125 pag lacus 0 Sutjob conaons) and Fgh fre ol pressures at 280 fo 300 pig, Al the oll pump nozae pressure qauge fest por. Retor tothe ‘Sumer Spectieason sheet shipped uly the burner andor page ‘34, Table 9 for tigh the 08 pressutes and Now Tats, ‘Theol pump depiced inthe ol lw schematic above is as anufacured by Webster Electie Company ine. the pump ‘on your burner not Webster, rele to the of purp Buln Shipped sh the bums for specie ajusiment information ‘Also see page 12, Figure 1 Noe 2 ‘Component operational sequencing wil vary wih the specie Flame Safeguard Contol being usod. Root To ho spect Flame Safoguara Control bulletin supplied wih the burner for ‘compete lvormston,Fg BS Figure 26 Gas or Gas/Oll Burner Fuel/Air Promix Adjustment - Gas, Oil or Gas/Oil Burner Diffuser Adjustment CGasitir Premix Adjustment Knot Blast Tube Difuser Position Adjustment I d A 5 t Gas niet, FUEL AIR PREMIX ADJUSTMENT(OPTIONAL) ‘The adjustable premix blast tube (optional) incorporates an adjustable gas/ai premix within the burner fring head. The premix configuration Is primarily used for cyindtical combus- tion chambers or high heat release pressurized freboxes. Moving the adjustment knob back increases the premix alr Figure 27 ‘moving forward decreases the premix ar. Generally, he ‘best (quitest/smoothest) operation Is in the ful forvatd positon with minimum prembs ait. The premix adjustment fs sel al the factory in the full forward positon. To attain the best combustion resuls for speci job conditions, change postion in small increments. DIFFUSER POSITION ADJUSTMENT ‘Moving the blast ube dfluser assembly fore or aft on gas (Fol fiing will move the flame front (point of retention in ‘order to aliain the best (quilest/smoothest) combustion for speciic job condions. Ifthe iil midway point factory setting does not provide satisfactory resulls, move fore or aft In small Increments to achieve the best combustion Fesuls. Ir unit Is oll or combination gasioll, the atached, flexible copper oll nozzle line will move fore of aft with the assembly. When fring on ol, moving the assembly forward wil tend to broaden the Name pattem and moving ‘Uack wall narrow the flame pattern. Similar results are ‘oblained on gas, but observation of sound and combus- tion fests are the best determinants of resuls on either 938 oF oll. Gas/Oil Linkage Adjustment For Full Modulation Standard System DE 2 D@OOE Figure 28 ‘Typical general linkage arrangement for combination ,gasioll full modulation burner, showin in low fire light ‘ff position. Dotted lines indicate approximately high fire position. When making adjusiments, make certain the motor can make ls full 90° stroke without any linkage binding, Driver Arms (A) connected to the Modulating Motor (1) Jack Shaft (2) will increase the travel of the Driven Arms {@)as the Linkage Rod (C) ball joint is moved away from the Jack Shaft, The travel ofthe Driven Arms wil be Inereased as the Linkage Rod ball joint is moved toward the shaft of the driven device. 1 Modustng Motor |. Diver Arms 2. Jack Shatt 8. Dien Ams 3. Modulsting V Pot OW vate Linkage Rods 4. Modulaieg Buty Vabe Gas/Oil- Detail and Adjustments on Modulating Varicam"™ Characterized Fuel Metering System. Mosultng rer Casvahe Gas Fuat Baer em (as Ful Dien em cas Fut Unkage Rog camSeew #12 Gas Fuel Cam arm ‘head binging Set Sew (Gas Fuel Cam Fotowor 8 Fst Cam km ‘Ae Damper Linkage Red ‘Ae Damp Orion Am (Ful Cam Fosower For complete adjustment instructions refer to bulletin YA1B88 Varicam Adjustment Instructions included in the information shipped with the burner. Modulating Mote Dever Arm Jock Sha ven Am Modulating Motor Bracket Typcal Cam Spring } ack Sat | ae Damper Housing } ot Fucicxer arm | on Fuel Linkage Rod {oi Fuel Daven arm pouting 01 Vatiec23 ree GENERAL START UPPROCEDURES-ALL FUELS Al Fuels - General Start Up A thoroughly Quali Bune: techiian should be ‘employed to provide the inal burner stant up, a8 well as, any subsequent servicing. ‘A representative of the owner andr the person or persons responsible for operating and maintaining the un should be present during the ital slat up. & sence represent ‘te may also be required by the local uty on gas fred ‘equipment. Instructions regarding the proper care and maintenance of the unit should be outlined with these people present, Before beginning stat up, the start up technician should thoroughiy sludy and become completely Tamia with the exacl Sequence of operation and all cher details of the specif lame safeguard contol stem being used This information wil Be found in bulletins printed and supplied by Honeywel or Freye, A copy of tis bulletin was supplied with the burner. ‘tor the burner is mounted and all wiring and piping has. been completed, tested and determined to be correct, the folowing procedures are recommended: For combination gasioll units; the gas side operation should be set up frst to clock the gas meter, allowing precise gas inpuls tobe determined. Once the gas ope Fallon complete, the of sie can bese up easly by Correlating the CO; values ofthe to fuels. See page 4 able 13, COO; Ratio Curves for Fuel Oils and Gases. Its anticipated that the GasyOll bumer val rarely run on ‘its recommended that the blower motor dfven oll Bump drive coupling be removed a resaced oy ‘When required fr ol ring. however, the pump coupling is let connected fo the blower moter, It's essential 10 ‘ensure that the pump has a good ol Supply, when the burner is operating on the gas cycle, so that Iwill nat run ary. Be certain on initial start up that the pump Is ‘adequalaly primed fo prevent against mechanical sete caused by lack of oll The pump waranty willbe voided ithe pump is run without adequate of suppl. Seat eran enema re tatar en eames nm co Soe el Uma eat Go ear ry ae ar oe Ae a Gra or eur Si caren gion aie ik ele at ecto age Seced te od cer agate Besetrges eure eae na a separ olga ay teeta Freee aes eee ae 2. Close main and checking gas cocks. Open suction line manual oll vakes and others as appropriate 3. Tighten all screws on terminal blocks in contol cabinet in ‘case some may have loosened in shipment, 4. Do not secure lame safequard control int its wring base Until it has been determined that there are no shots oF ‘grounds in the system, 5. Check fuses in main panel and in bumer contol cabinet, (Check wiring fo the bummer contol cabinet for complance with the wring dlagram and focal codes, Determine that voltage supaly is cortect ta motor starter ine connections ‘and fo control creut line connections, Ia contal circu transfoimer is supplied, make certain its primary votiage matches the tine voltage being supplied. (A 230 voll. rslomas does rel produce proper conl wage when supplied wih 208 vols. 6. Check breaching and stack to ensure that they are open ‘and unobstructed 7. heck owes ond ol pump matt as appt) ation bby momentaly mallng conlact ofthe motar sare. Propet tar pied Ge fan ous nd supe) the remaie all purnp sel assembly 8, Chock operating cons iit conto ow water cu fame sled cont reset, igh and ow gas prossie sifiches (used) and lw re interlock switch ke and and al oer applicable inelocks, A contac si {an exceplion wil be ound on aps using he cow eas pressure Sitch: fis swiich Should be open unl the mln ‘gas cock is opened, Ia low all pressure Such i used, iS contacts val remain open untlthe of pump is running and the low oll pressure cutin point is reached 9. Do not repeatedly recycle the burnes, so as to allow any tunburned uel In the combustion chamber 10. Speci instructions relative to component sequencing ate eeiged ns tame saequard arate Sich nciged vin te docimenttin shppes wh he burner ler Honeynel ard eye Rate regaring fhe np ang oD sites nce tin lh the pot statshng pestod, tame ale son, are a How Sten fate fates 11. Proper test equipment must be used in oder to achieve maximum system operational relabity and fuel effcien- Ges, See page 24 for equipment Isis 12. Allfueir adjustments should be made to achive 1 Input rate, satisfactory combustion test values, flame stablity and appearance 13. Every new burner start up should employ the use of the Bumer Siar Up information and Test Data sheets on pages ag and 47, Information on Fuel/Air Modes of Operation for Combination Gas/OIl Units (also see Section 3, page 15) General Information Speci adjustments and mechanical operation of the various modes of fuel/air control for straight gas and straight of burners are included in this manual. This. information should be used to propery adjust each fuel for combination gasioll units. The fllowing information Is offered as additional guidance. Gas On/Off System Combined with Ol On/Off System The air dampers are adjusted and lacked in place for the most efficient operation for both fuels. Refer to the ‘mechanical operation ofthe Gas OnvOf and Ol OrvOF systems for adjustment details (pages 15, 16 and 17). Gas On/Off System with Ol On/Off Fixed Ar Low Fire Start System ‘The alr dampers are adjusted and locked in place for the ‘most efficient high fre operation for bath fuels. Smooth light ‘off on gas fs achieved by the use of a slow opening dlaphyagm ‘er moiorized gas valve, which, once energized, allows gas ‘low to steadily increase from the Intl ight of volume Up to the high fre volume. Smooth light off on ols achieved by the use of a solenoid ol valve bypass system which allows a reduced amount of oll to be burned at light off and then switching to the high fire rate once the low fre has been established. Refer to the mechanical operation of the Gas (On/Oft system and the Oll Fixed Air Low Fire Statt systemfor specific adjustment details (pages 15 and 17) Gas On/Off System with Oil Reduced Ar, Low Fire Start RALFS See page 18, Gas Low/High/Off System with Cll Low/High/OMt System For Gas - movable alr dampers are adjusted to provide a smooth light off position and then moved to the high fre postion through mechanical linkage from a motorized gas, valve, The alr dampers are adjusted to open to provide ‘maximum combustion efciency atthe gas high fe input rate. For oll the same ar dampers are operated by a hydraulic all cyinder which, through mechanical finkage, Is adjustod to provide a smooth ight of and then open to a point where the highest combustion efficiencies wil be achieved at the high fre input rate. Smooth oil ight of is further achieved by the use of a solenoid oil valve bypass system, which allows a reduced amount of oll to low al igh! off and then stitches to the high fre rate (Simultaneously energizing the hycraulle ol cylinder) once low fre has been established The mechanical linkage from the gas valve Is physically arranged so that the hydraulic all cyinder (which is non- ‘operational when burning gas) has no effect on the gas linkage adjustments. Similarly, the gas valve (which is non operational when burning oi) has no effect on oil linkage adjustments. It should be nated that when the hydraulic o| tylinder moves the ale dampers, the movernent of the air ‘dampers wil cause the motorized gas valve lnkage to move Up ang down withthe opening and closing of the hydraulle ll cylinder. The motorized gas valve linkage is tree floating, f’and even though it maves wih the ol eyinder operation, it cannot cause any gas flow to pass through the motarized {gas valve, Refer to the mechanical operation of the Gas Uow-tign-off system and the Oil Low High-Oft system for specific adjustment details (pages 15, 19 and 20), Note The oll sige operation can be supplied wih either a Suntec ora Webster ol pump. Ree othe mectancal opalion fr tha speci system for cjustment deta Gas Low/High/Low System with Oil Low/High/Low System Refer to the above explanation of Gas Low/High Ot Systern ‘and Oll Low/HighiGtt System. The Gas Low/High/Low ‘Systems are dniical in operation, except that an adaltional lemperature or pressure contol is added to the system, which ata selected preset point wil electrically such the motorized {gas valve (which isa diferent model ruber than the LowhHigh/Oft motorized gas valve) to an adjustable Low Fite postion. This low fre positon fs an adjustment that is designed internal to the gas valve and, depending upon the specific manufacturer of the valve, willbe found eller in the valve wiring compartment of under a removable cap fn top of the valve, Refer to the valve manufacturer’s Burner Start Up and Service Test Equipment Required product buletin supplied wth the burner for specie deta For tha LawitighfLow systom oll side operation the ddtonal temperate or pressure conte wi also cause the solenoid olf valves, hydraule ol cylinder and ait ‘dampers 10 go 10a fow fre postion atthe same preset temperature or pressure a the gas side operation. The ‘ail side low fre position is one and the same positon as {he ight of positon, Le. the ae dampers and ol pressures have identical settings (3s Compared to the gas side which can be adjusted. f desired, to have aferont settings for fight of and iow fre). Rete tothe mechanical operation of he Gas Low-High-Low system and the straight Ol Lowe High-Low system for specie adjustment dotals (Gages 15,19 and 20). Note ‘Tho alse operation can be suppled with thera Suntec ora ‘Webster ofl pump. Refer io the mechanical operaian forthe Specie syslom for adjustment otal Gas Full Modulation System with Oil Full Modulation system ‘The Gas system uses an automatic diaphragm or motorized gas shutott valve {o contral the onvoft flow of the gas, The Oil system employs an ol solonold valve to ‘contol the onvof low of ol to the oll nozzle. A modulating motor controls the modulated positioning of a butterfly type Gas Proportioning Valve while a V ported metering ‘ll vale provides the modulating function inthe oll nozzle return line. The modulating motor also contvols the postioning of the combustion air dampers, through ppropriaie sequencing - providing low fuel/air input for ‘a'smooth low fio start and an infinite number of fue/ait postions between full low and high fre. Additional finite fuclak adjustments are provided when the optional Power Flame Varicam™ characterized fuel metering system is, used (optional. ‘When fring Gas the cit metering valve wil open and close because Is inked to the modulating motor: however, the 6 solenold shutoff valve remains Closed, and no oll is allowed to low to the nozzle. Similarly, when fring Ol, the butterty gas valve wil open and close because I inked. to the modulating motor; however, the main automatic, gas supply shutofl valve (motorized or dlaphragm type} Femains closed, so no gas is allowed to flow fo the burner head. Refer to the mechanical operation of the Gas Full Modulation system and the Oil Full Modulation system (pages 16 and 21, as well as page 22 entiled Gas/Ot Linkage Adjustment Full Modulation - Standard System) for specific austment deta. ¥ supplied, aso refer to page 22, covering Detail and Adjustments on Modulating Varicarn’* (Characterized Fuel Metering System. ‘The folowing test equipment is required to ensure proper start-up and adjustment of burner equipment fo For Any Fuel For Gas ‘obtain maximum efficiency and rellabllty of operation, See page 40 for CO,/0,/ Excess Air Curves. For Ol 160, indicator or 0, analyzer CO Indicator stack thermometer Ucube manometer or alt Draft gauge or inclined brated 0-10" and 0-38" WC manometer pressure gauges Combination volv/smmet (Higher pressure ranges may meter be necessary depending upon D.C. miereammeter or D.C. as riot soply eeesaura) voltmeter, 2s required by Flame Safeguard programmer selection Compound vacuum/pressure ‘gauge - 0-30" vacuurv0-30 PSIG. 0-400 oil pressure gauge (wo required for intemal bypass Iype ‘ll nezzles) ‘Smoke testorNote \Whon fing gas fuels, is possible to ata CO, readings that appear to te acceptable (2, 8%, 9%, 10%, etc) whe actualy producing an unsafe conlién. At such CO, readings, a Sefeiency ofa wil reat the formation of CO (esrbon 25 Revol monoxide) In the fue gases. Therefore, when fring gas; est for {Co'ta make certain thatthe burner Is sdusted so tat thas an ‘excess, rather than a defcierey, of af. CO is 8 dangerous, produ! of Incomplete combustion and fs associsted with ‘combustion ineficency and increased fue cost GAS STARTUP NOTICE Refer to page 23 General Stat Up Procedures - Al Fuels and Section 3 for mechanical operation detall of specific modes of burner ‘operations. Combination Gas/Oil systems should also reler to page 23, Information on FueVAr Modes of Operation for Combination Gas/ON Units General Information ‘Some applications may require the burner to function at the low end ofits rated capacity. Asa result, the two combustion air inlets may Supply more ar than Is requied for effcient combustion, In such instances, It may be deskrable to operate the system using only one combustion air inlet and one combustion air inlet damper. This may bbe accomplished by removing cross connecting linkage between dampers and locking the unused damper in a fixed, closed position. One way of lacking the damper Is, to use a 10-24 machine screw through ihe hole In the linkage arm, and dil and tap the air inlet housing, of use. two nts on the screw and let the screw bear against the ‘Burner Start Up Sequence Instructions 1. Prior to burner star up - contact the focal gas company to determine if any correction factors hav {o be applied fo thelr indicated moter ow rates. Thi Information Is important as relates to achieving specie heat exchanger BTUMHR inputs. Refer to page 41 (or additional combustion analysis information and to page 6 for firing rate information. 2. Refer to the gas piping diagram furnished with the burner. Check gas piping, contols and valves lor leaks and compliance vah codes, 3, Check all inkages. I'he system Is a packaged bumer! heat exchanger system, the linkage was probably sot ‘when the system tas test fred af the heat exchangor manufacturer’ factory. should, however, be checked to ensure that It was not damaged in shipment, On conversion unis (where the bumer and hest exchanger fare mated inthe fel), the linkage wil have to be set to sult the paricular operating conditions. 44, Do not secure flame safeguard contrat into its wiring base unillt has been determined that there are no shorts or grounds in the system, 5. Remove the pilot assembly and chock for proper settings of the spark gap, ightness of electrode ka its bracket and firm connecilons of the electrode cable. (Gee page 29 and 40) 6, Close main, checking and pilot gas cocks. Install one (gas pressure gauge 1 read eumer fring Nead pressure (se a 0-10" WLC. gauge ar a manometer). See Section 3 for pressure sensing locations. Install a second gas pressure gauge to read gas supply pressure between the main gas Cock and the Inlet o the main gas pressure regulator (use a 035" W.C. gauge ar as appropriate) IF there is no tapping in this Focation, instal a Toe athe point where the pilot gas supply is connected to the ‘main gas line. Slowly open the main gas cock in order ‘ak inlet housing Air dfuser movement (ore and aft) may be necessary to [produce the best flame pattern or smoothest operation. See page 22 Gas, Oil or Gas/Oll Bumer Difuser Adustment fr further information, ‘Gas and Gas/Oil burners for Scotch marine and other selected applications Incorporate a gas/air premix ‘adjustment. This adjustment Is identiied by diametrically ‘opposed adjustment knobs on the blast tube. See page 22 Gas or Gas/Oil Burner Fue/Air Premix Adjustment or further information, to determine that the incoming gas pressure is within the specified limits ofthe main and pilot gas pressure regulators, automatic fuel valves and gas pressure ‘suiltches. Many systems are rated for a maximum gas supply pressure of 14" W.C. If pressure exceeds Inls, value, consult the fist page of the Burner Specification Sheol and/or gas component product bulletins supplied vith the burner to ensure thatthe supplied system can operate property atthe elevated supply pressure. 7. Disconnect pitt tine a inlet to the pilot gas pressure regulator and purge alr from the plat gas line. Purging ‘of gas lines must be done in accordance with NFPA 5¢ of the National Fre Protection Association's National Fuel Gas Cade. After the ar is purged from the gas supply system, close the plot cock and reconnect the'pilat line. Leave the pilot cock closed. 8 Install required system measuring devices: 3} appropriate fame signal meter fo the fame safeguard Control} manometer (or 0-10" W.C. gauge) in ne plot teste pot) slack thermometer and CO, oF O, same line tothe breaching: and a) drat gauge to the combustion chamber test point 9, Is strongly recommended thal an automatic gas valve bubble feak lest be performed in accordance with the {gas valve manufacturers instructions on every new installa and periodically afterwards in order to tensure thal the valve is functioning according to the rmantfacturer’s specications. its also suggested that the lest be conducted during 2 normal prepurge burner ‘operation, This test wil reveal any problems that relate to incorrect wiring ofthe automatic gas valve that coula cause premature energization of the vale, % Note: though Underurters Laboatries permis higher tradi of Cb (Catton Manoa Ws dara oan Sn et exchariger manuacurer's tecommendaions.10. Set the alr dampers approximately 1? open, and with both pilot and leak test gas cocks closed, apen the ‘main gas cock (o allow the low gas pressure switch, IF supplied, to make ts crcut). With the control swatch In the Of postion, apply power to the burner through the main bumer disconnect switch. Seitch the burner panel On/Off switch to the On position momentary to determine that the blower rotation is correct. 11, Restart the burner. Pertcm an Il spark pik test Wh the pllot gas cock closed, te bane w go through a blower prepurge poto, afer which the gas plot tgntion transformer il be energized, though ne pot wil be estabshed. (A no tie Should there be ay fame signal reading. nex the rain gas ve stem fo open) Aine endo te plot tal or gato and Boner Purge pero, te femme Safeguard contra shou shut he system down ina safely lockout mode, requring manual reset of tho lame Safeguard convol to restr the ures. 8 Momo signals detocied, very the fame reterion {ab and inion electrode ae property postoned, por Figures 2327 on pages 26 and 3 12. Wail three minutes, reset the flame safeguard contro safety switch (restating the burner) and open the pilot gas cock. When the blower prepurge period fends and the burner Is energized-I the flame safeguard contvol has a stopitun switch stop the timer wile the plat ison, visually check the pilot flame size and stability and make adjustments as required. See page 39 for pilt igntion adjust- ‘ments. Ifthe pumer has automatic air damper ‘operation (dampers moved by the automatic 93s valve of modulating motor) and the Flame Safeguard Control does not have a timer stap/run switch wil bbe necessary to keep the air dampers in the pilot light off flow air flow) position by temporarily electrically disconnecting the motorized gas valve ‘oF modulating motor to complete pilot adjustments. Recycle the Burner several mes to make certain pilot operation fs rolable 13, Wi pl asstments completed reset the timer switch to the Run position, which wil allow the Sequence lo proceed to the aulomalic gas valve energizing postion. If the motorized gas valve or modulating motor wires have been disconnected, Shul the burner off and reconnect electrically to allow normal automatic air damper operation Burners Designed for Full Modulation Operation u 18 16 uv 18 9. 20, ‘When the main automatic gas valve begins to open, slowly open the checking gas cock to light off the main lame. The main flame should ight immediatly. I nol, it ‘may be necessary o eliminate ar rom the main gas tne andor adjust main gas pressure regulator flow rates. Agjust the bumer as necessary fo provide smooth ignition of the main flame. he flame signal drops significantly when the main automatic qas valve opens, ‘lightly increase the pilot gas pressure to attain a slable Mame signal value, For On/Off burners - adjust the main gas pressure regulator to achleve the proper maln flame gas input ‘Sel and lock the ar dampers fo provide 8; 10 10% CO, (Carbon Dioxide) and ite or no* CO (Carbon Monoxide). ‘Make ceriain the gas pilot operates cellaly at the final fuelai settings, For Louihigh'Of burners - adjust the main gas pressure regulator In combination withthe alr damper linkage operation to achlove 8 to 10% CO, (Carbon Dioxide) {and ite or no* CO (Carbon Monoxide) at the full high fre Input rate poston. Make cetan the Inkage operates smoothly and without binding or overvavel of the ai ‘damper stops. For Lowitigh/Low burners - adjust the main gas pressure regulator in combination with the alr damper linkage ‘operation to achieve 8), 1o 10% CO (Carbon Dioxide) ‘and litle or no* CO (Carbon Monoxide) atthe ful high, fre Input rate postion. Make certain the fnkage operates, smoothly and without binding or overtravel ofthe air {damper stops. Run burner to the low fite posiion and. lock motorized gas valve intemal ow fire adjustment to 2a setting that vill attain 7 0 9% COs af the desired low fire input rate. Intermitently operat the burner until the water is warm in the baller, or folow specific nil fring recommendations provided by the heal exchanger manufacturer ‘Sae tems 22 through 26 in ths section for recommended limit control and olher control devices operational checkout, ‘See nate on Page 25, After completing pilot adjustments and other proce- dures as appropriate in ems 1 through 16 above, proceed with modulating adjustments as follows: 21. Initial adjustments should be made at the low fire postion. all Power Flame bumes are factory tested and adjusted. However, to determine thal the metering buttery valve Is, in fac, inthe low {ire position, observe the end of the metering valve shaf. The slot in the end of the shaft Inleates the postion of the valve. When the slot 's inthe horizontal postion (paral with the gas flow direction), the valve is fully open. Refer to page 22, Figure 27 for linkage adjustment Information and page 22, Figure 28 for adjust- ‘ment informaton on the Varicam™ characterized fuel metering system. 22. 23 “Tum the burner on and let advance to the main fame light off positon. Take action as necessary to hold the linkage atthe low fe postion by using 2 manual potentiometer or electrically disconnecting the modulating fotor. Power Flame burners are tested atthe faclory and. linkage adjustments for modulation are made at that time. Note that the factory setings relate to good ‘operation while fring into open test pits, and therefore ‘wil normally nat relate directly to absolute fuel raios while thing Under specific eld conalions, I is suggested thal the factory settings be noted and marked on the linkage prior td proceeding with final adjustment. In this ‘manner those settings can be restored as inal reference points, need be. withthe burner in the factory se low fre posiion, aust alr and fuel Iinkage to good fuel/air ratio low fre setings24, 25, 26. 21, 28. 29 30. a 32, (7 - 9% COs Ite or no" CO). Mark he inkage atthe new settings Increase the fing rate to the midway pain. Sel the tear ‘atos 10 achlsve ood combustion values (79% CO,, Ile ‘or no* CO), Mark the linkage as a reference path (this ‘new mid fe position. Increase the rate to high fre poston and repeat the test done forthe mic point adjustment. Resus should ange in ‘he area of 8's to 10% CO,, with ile or no* CO, The me- ‘ering device setthng and alr damper openings shoukd be marked and noted to obtain high fre reference points. Note that an addtional point of the tre adusiment may be ‘obtained by modtying the reguialed gas pressure delver- ‘ed lo the burner mefering device. The burner pressure ‘regulator is used to obiain this adjusiment and can be used within available pressure mis (0 oblain optimum {ring conditions, Operate the modulating lever arm on the modulating motor through the three previously referenced points. Minor seting modifications may be required to ensure that the reference points are acquired. Tighten (finger tight) the hex bolt to the linkage rod at the suivel on the modulating motor crver arms and run the motor through i ul avel fo ensure that the Inkage Is free and thal limits on the metering device and air dampers are not exceeded Determine thal the required gas input rate Is being achieved by clocking the gas lw al the gas meter.The {98 ullity should be consulted to determine f any Correction factors have to be applied to the indicated meter flow rates. Refer to page 41 for addtional Combustion analysis information and to page 6 for additional fring rate Information, Intermittently operate the burner unl the water is warm in the Boller, oF follow spect initial fring recommen dations provided by the heat exchanger manufacturer. Tighten all nkages and permanently mark settings Limit control check should be made as follows: 1) Pernt the burner to run unil the Imit contro settings have been reached. 1B) The bumer should tum off when the set temperature or pressure has been reached. Ifthe burner is Low! High/Low or Modulating, set the controls so thatthe burner wil go to the low fire position before the ‘operating tit control turns the burner of. CC) Altera dffereatal pressure or temperature drop, the burner should restar automatically, Wn the unit running normally, apen the blow down valve and remove water to the point below the Low ‘Water Cut Of Seing. The burner should tum off and Testart automatically when the proper water lovel is Feestablshed. (Wa manual reset ype Low Water Cut Off is used, It wil have to be reset) 0) ‘Sel and check operation of ‘A) Low and high gas pressure switches. See gas pressure switch manufacturer's insinictions for Getalled procedures. Units with mercury switching ‘device must be propery leveled. (1) Forint startup: Once the burner’s normal operational gas pressure has been set, adjust the low and high ‘gas pressure swlfches as follows: (@) Low gas pressure switch. with the bumer ‘See note on Page 25, 33 34 35. 27 ‘unning, slowly close the main gas train ‘manual shutoff cock and adjust the switch to open Its citcult when the pressure falls below is nosmal value. The bumer will shut down, Open the manual gas shutof cock to the ful open position and manually reset the Low Gas Pressure Switch, The burner vill restart. (8) High gas pressure switch. With the bummer running, adjust the switch 10 2 point whore the switch opens its cirult. The burner wall shut down. Manually ceset the switch and readjust the cutout point to be made at the normal operating pressure, but 10 open it the pressure goes slightly above normal 8) Al bumer and heat exchanger controls and operating devices. ) Blower Combustion Air Flow Switch () Shut bumer power off @) Disconnect both wiros a the ac ow switch and ‘temporal clip them together. Make sure that they cannot ground against anyfing, since they wi be powered with 110 volts during the test (@) Puta continuity meter across the common and normally open terminals on the air switch. () Close the gas train checking cock. (©) Start the blower motor. The meter should read ‘lecrcal continuity as soon asthe blower starts. © Disconnect the blower motor lead wire or the ‘ro which energizes coll of motor relay starter, or open the main power disconnect switch the burner Within 4 to 5 seconds after the blower motor is de-enesgized, the meter should indicate an open airflow saitch circuit (no continuity), () Ifthe switch does not open in 4to § seconds, readjust accordingly, Turn the ar flow switch adjustment screw clockwise to shorten cut-off response time, and counter-clock-wise to lengthen cutoff response time, (®) Tum the burner power off. Remove the shoring clip from the two disconnected wires and let them hang loose, (They will be powered with 110 vols, so dont let them ground out) (@ Open the gas tain checking cock. Turn the bumer on, With the wires disconnected, the burner should go into a purge cycle, although nelther the ignition nor the main fuel valve Circuits wil be energized. If they do energize, there Isa wiring problem, Correct as requred, (10) Tur power off. Reconnect the air ow switch wires to the air flow switch terminals, Place burner back into normal operation, The Owner's Operating instructions, page 61 ofthis manual, should be posted in a clearly visble location cose to the burner. the burner operation is abnormal, refer to Section 7, Trouble Shooting Suggestions, as well as trouble shooting information included In the flame safeguard manufacturer's bulletin shipped with the burns. tis also strongly suggested that al test procedures uted In the flame safequard control manufacturer's bulletin be conducted Complete the Bumer Start Up Information and Test Data sheets on pages 46 and 47