S_Burner Manual
Contents
1. Figure 9 3 Inlet Air Damper Adjustment Section 9 Inlet Air Damper On burners equipped with an inlet air damper the airflow through the burner is limited by the position of the inlet air damper blades If the air blades are too far closed during high fire the burner will be under fired even if properly tuned A general rule is that the air blades should be at least 80 open when on high fire On Johnston S Burners the inlet air damper is between the silencer and the air inlet housing Fig 6 1 The inlet air damper controls the amount of air let into the blower For burners with a parallel positioning system the air damper is controlled directly by the burner programmer which in turn control individual motors located directly on the damper shafts see Fig 6 1 For burners with a single point positioning system linkages from the MOD motor are used to control the inlet air damper These linkages may be adjusted as follows e To decrease the amount of air let into the burner increase or decrease the length of the linkage rod to obtain a larger angle between the rod and the linkage arm This will decrease the amount of rotational travel for an equal amount of travel made by the arm e To increase the amount of air let into the burner increase or decrease the length of the linkage rod to obtain a smaller angle between the rod and the linkage arm This will increase the amount of rotational travel for an equal amount of travel mad2. Assembly Drawing Burner Trim Components PURGE AND COMBUSTION AIR SWITCHES FLAME A SCANNER NTRO R A We JACK SHAFT Sa AND LINKAGE SET edi Fig 6 2 Section 7 Fuel A Main amp Pilot Gas Train Pilot Gas Train Fig 7 1 Manual Manual valve that controls the Shutoff Valve gas supply to the pilot train Pressure Reduces the incoming gas Regulator supply pressure to meet the lower pressure requirements of the pilot Shutoff Electric normally closed valve s Valves when energized open to admit gas to the pilot One or two depending on insurance code requirements Pressure Indicates the regulated gas Gauge supply pressure to the pilot assembly Vent Valve Electric normally open valve closes when energized when req d Relieves pressure between normally closed valves Main Gas Train Fig 7 1 Main Shutoff Upstream shutoff cock at Cock entrance to the main gas train Manual valve that controls the gas supply to the train Supply Reduces the incoming supply Pressure pressure to meet the lower Regulator pressure requirements of the main burner and eliminates any fluctuation in the gas supply pressure Regulated Indicates the regulated gas Pressure pressure to the main gas train Gauge Low Gas Opens under a low gas supply Pressure pressure condition Will not Switch allow the burner to operate under this condition Safety Open t
3. 6 Check for fuel and air leaks Any leaks in the piping fittings controls should be attended to promptly Replace failed indicating lights and ensure that all alarms are operational Maintain a clean orderly and safe boiler room Di Section 10 Weekly The following maintenance tasks should be performed weekly by the operator 1 Check the burner linkage joints arms and rods for tightness Check the linkage firing rate motor MOD motor shafts bearings and flow control fuel valves for proper and smooth operation 2 If a heavy oil burner clean the oil gun assembly In cleaning the oil nozzle disassemble and clean with solvent and compressed air 3 Grease the burner blower shaft bearings sparingly only while in operation See the manufacturer s recommendations for lubricating the blower motor 4 Ifinstalled check the boiler outlet flue gas damper for proper and smooth operation 5 Check the peepsite and sightports for cracks in the lens Monthly The following maintenance tasks should be performed monthly by the operator 1 Check the burner pilot assembly for cleanliness and proper condition Check the electrode for cracks in the porcelain and proper adjustment Check the condition of the lead wire and its connectors Standard electrode setting is a 1 8 to 3 16 gap 2 Check the flame scanner for cleanliness Check the condition of its connecting cable 3 If a light oil fired burner check the oil
4. L2 for Honeywell RM7800 firing light oil or gas L1 amp L2 for Honeywell RM7800 firing heavy oil Improper Gas Supply To Pilot Regulator a Upstream valves must be open b Excessive pressure to regulator can cause regulator lock up Improper Electrode Spark Gap Adjust electrode spark gap Broken Electrode Insulator Replace electrode insulator Blower Dampers are not Closed Faulty Pilot Solenoid Valves Faulty Ignition Transformer Close blower dampers Replace faulty pilot solenoid valves Replace ignition transformer Faulty or Disconnected High Voltage Lead from Ignition Transformer to Electrode Connect lead from ignition transformer to electrode with electrode Section 12 PROBLEM POSSIBLE CAUSE SOLUTION PILOT FLAME IS Run Check Switch Set to Run Position ESTABLISHED AND in Check Position PROVEN FOR 10 SECONDS BUT MAIN FLAME NOT ESTABLISHED FUEL VALVE LIGHT ON Faulty Flame Safeguard Check for 115V between flame safeguard main fuel terminal and neutral 7 amp L2 for Fireye E110 and 9 amp L2 for Honeywell RM7800 Fuel Control Valve Actuator Defective Replace Fuel Control Valve Actuator Auxiliary Main Fuel Valve Actuator Defective Replace Auxiliary Main Fuel Valve Actuator Manual Oil Valve at Burner Closed Oil Only Manual Oil Valve at Burner must be Open Incorrect Burner Adjustment Oil Se
5. Email ewessel johnstonboiler com or service johnstonboiler com Donna Utzman Phone 616 842 5050 ext 317 Fax 616 846 6380 Email dutzman johnstonboiler com Section 6 About the Burner A Introduction Thank you for purchasing a Series S burner from Johnston Boiler Company All Johnston Boiler products are designed and manufactured to give excellent efficient performance over a long period of time All items supplied were chosen because of their ability to give high quality performance Proper operating and maintenance procedures must be followed at all times to ensure a high degree of protection and safety Operation of this equipment should not be considered free from all dangers inherent to operating a steam hot water vessel with the firing of a combustible fuel The operator is solely responsible for properly maintaining the equipment No amount of documented instruction can take the place of intelligent thinking and consistent safe practices This manual is not intended to relieve the operator of the responsibility for proper operation The operator must be familiar with all components and operations of the burner Identify and locate each component while reading this manual B General Burner Description The Johnston Series S burner is available in gas oil and combination gas and oil designs Special designs are available for burning waste oil tallow and low btu gas Series S burners are engineered for firetube and w
6. fired burner Johnston Boiler Company recommends a maximum 2 Smokespot Ringelmann Chart in its oil fired burner Air Properties For a burner originally adjusted to 15 air changes in combustion air temperature and barometric pressure cause the following in excess air Air Barometric Resulting Temperature Pressure Excess Air In HG 40 29 25 5 60 29 20 2 80 29 15 0 100 29 9 6 120 29 1 1 80 27 7 0 80 28 11 0 80 29 15 0 80 30 19 0 40 31 34 5 60 30 25 0 80 29 15 0 100 28 5 0 120 27 5 5 Expressed as a percent of the Stoichiometric air required Section 10 Maintenance A General A good maintenance program is essential to the lasting operation of your Johnston burner Properly maintaining the burner will reduce unnecessary downtime lower repair costs and increase safety All electronic and mechanical systems require periodic maintenance Automatic features do not relieve the operator from maintenance duties Any unusual noise improper gauge measurement or leak can be a sign of a developing problem and should be taken care of immediately B Component Specific Maintenance Most of the components and systems of your Johnston burner require little maintenance other than regular inspection Cleanliness is essential to the inspection of the burner Keep the exterior free of dust Keep the controls clean Clean dust and dirt from the motor starters and relay cont
7. gun assembly for cleanliness and condition Clean as may be required In cleaning the oil nozzle disassemble and clean with solvent and compressed air 4 Check the blower assembly condition cleanliness and proper operation including the motor blower wheel air damper and linkages 5 Ifa heavy oil fired burner check the operation of the steam trap for the oil preheater 6 Ifa gas fired burner check the main gas valves for proper smooth operation 7 If a combination fuel burner check the fuel selector shifter mechanism for tightness and proper operation 8 Check operation of the surface or continuous blowoff valve 9 Change oil in air compressor after 500 hours of operation Annually The following maintenance tasks should be performed annually by the operator 1 2 3 Check the condition of the burner internals including the swirlers main gas ring oil gun assembly and burner refractory Check gauges and thermometers for proper calibration Open clean and inspect the burner fireside Inspect the condition of the refractory Hairline cracking in the refractory is normal Loose or missing pieces in the refractory must be patched repaired or replaced Check the condition of the fireside gasketing Check for hardness and or cracking Replace fireside gasketing as needed but not less than every three years Section 10 BLOWER BEARING Lubrication Instructions All SEALMASTER bearing units are prelubricated with
8. up and the burner will travel to high fire more quickly 3 Adjust the fuel flow through the characterized fuel control valve This is done by matching the fuel flow with the air flow at each point through its travel range Consult fuel control valve manual for adjustment instructions A parallel point positioning system allows the fuel and air to be introduced at varying rates This is the more modern method of fuel air ratio control and requires a modulation motor for each fuel control valve and one for the air damper Theses systems are computer controlled and require some experience to operate Only trained personnel should attempt to adjust or modify these settings The optimization of the fuel air ratio is essential to efficient operation of any burner Analysis of flue gases with proper instruments is the only way of truly optimizing fuel air ratio Johnston Boiler Company recommends flue gas oxygen levels of around 8 in low fire and 3 4 in high fire for gas fired burners Oxygen level recommendations for oil fired burners are around 6 in low fire and 4 4 5 in high fire Section 9 Johnston Boiler Company recommends no greater level than 200 ppm of Carbon Monoxide for both low fire and high fire The acceptable industry standard level is no more than 200 to 400 ppm of Carbon Monoxide Carbon Monoxide is an indication of incomplete combustion and or poor mixing Johnston Boiler Company also recommends no combustibles be present in th
9. while still allowing efficient firing This can be done by adjusting the FGR inlet damper and monitoring the stack Oz and CO to measure firing efficiency N Figure 9 5 Linkage Modification To adjust the FGR percentage first bring the boiler to low fire For burners equipped with a parallel positioning control system FGR percentage is modified from the burner programmer See programmer manual for information on adjustments For burners equipped with a single point positioning control system the linkages to the FGR damper must be modified Increasing the angle 8 as shown n figure 5 5 will increase the amount of FGR introduced off of low fire There is also a fixed shutoff damper in the FGR line It can be used to control the maximum amount of FGR introduced Gas Ring Adjustment If the burner is not firing correctly on gas after adjusting the fuel air ratio the distribution of gas to the inside of the flame may not be adequate Getting more gas to the inside of the flame is achieved by orifacing the gas spuds Consult the factory for proper orifice sizes to be used on your burner Oil Gun Location The location of the oil gun relative to the diffuser is important when firing on oil If the burner cannot be tuned by adjusting the fuel air ratio check the location of the oil gun tip The tip of the oil gun should generally be between 0 00 and 2 00 inches from the diffuser To adjust this start with the oil gun flush with the diffuser and
10. ATE MOTOR DOES NOT RESPOND Low Fire Hold Control Open Located In Boiler Shell Sensing Water a Check for proper setting 180 190 F before switch closes b Make sure switch closes when temperature rises TO MODULATING Temperature CONTROLLER Note Firing switch on panel set for Manual and manual potentiometer on panel set Open will override low fire hold control and allow firing rate to go to high fire Modulating a Check controller for proper setting of Controller Calling for desired steam pressure water High Fire but Firing temperature to be maintained Rate Doesn t b Check potentiometer coil and wiper Respond arm Note Manual Potentiometer must be set to Open position on panel and Firing switch on panel set to Automatic for modulating controller to operate Manual Automatic Replace switch Switch on Panel Inoperable Manual Replace Potentiometer Potentiometer on Panel Inoperable FLAME SIGNAL Burner not Adjusted Re Adjust Flame See Adjustment DROPS BELOW MINIMUM WHILE MAIN BURNER IS FIRING AND MODULATING FROM LOW TO HIGH FIRE AND VICE VERSA FLAME SAFEGUARD GOES INTO LOCKOUT Properly with Flame Pattern Changing Too Abruptly or Varying Too Much for Reliable Monitoring by Scanner Section Scanner Cell Weak Replace Scanner Cell Flame Safeguard Defective Replace Flame Safeguard MAIN FLAME SHUTS OFF DURING NORMAL FIRING CYCL
11. E WITH FLAME SAFEGUARD GOING INTO LOCKOUT Opening of Non Recycling Interlock Circuit Between terminals 3 amp P on Fireye E110 or 6 amp 7 on Honeywell RM7800 Check combustion air switch and low fuel pressure switches for abnormal conditions Main Oil Gas Flame Blows Out While Firing Adjust fuel air ratio See adjustments section
12. On accepted parts warranty claims Johnston Boiler Company will then cancel its invoice covering shipment of the advance warranty replacement part less any prepaid shipping charges Any prepaid shipping charges are due and payable by a customer in accordance with the terms of Johnston Boiler Company s warranty On rejected parts warranty claims Johnston Boiler will include in its written notification to a customer the reason why the warranty claim was rejected On rejected parts warranty claims Johnston s invoice covering the warranty replacement part whether advanced or otherwise is due and payable in the full amount by the customer All claimed defective parts must be returned to Johnston Boiler Company for warranty consideration no later than thirty 30 days after the advance warranty replacement part was shipped by Johnston On non warranty claim parts returns authorization to make any such return must be received from Johnston prior to making the actual return shipment Johnston will mail to the customer the pre numbered 3 part Return Authorization Tag This tag is then to be completed and handled in the same manner as a warranty claim Section 11 Johnston Boiler Company Return Authorization No Johnston Boiler Company Return 300 Pine Street Ferrysburg MI 49409 Freight Prepaid To S O Serial Model or Catalog Job Name Location Date of Return By This Item is being returned for the following conside
13. Table of Contents Johnston S Burner Section 6 About the Burner A Introduction B General Burner Description C Components of the Burner Burner Drawing Burner Trim Drawing Plenum Drawing Section 7 Fuel A Main amp Pilot Gas Train B Atomizing Air C Light Oil D Heavy Oil Section 8 Installation A General Information B Installation Recommendations C Boiler Room Air Supply Section 9 Startup Adjustments and Shutdown A Startup B Adjustments C Shutdown Procedures D Flue Gas Analysis Section 10 Maintenance General Component Specific Maintenance Schedule Lubrication Instructions Boiler Room Log moon Section 11 Parts Service and Warranty Claims A Parts and Service Policy B Parts Warranty Claims and Material Return Section 12 Troubleshooting Section 13 Customer Information A Drawings and Bills of Material B Reports C Component cut sheets SALES Contact Information Johnston Boiler Company 300 Pine Street Ferrysburg MI 49409 Boiler Burner Deaerators ancillary SERVICE PARTS Technical Support Or Field Service Spare or Replacement Pat Baker Phone 616 638 4737 Fax 616 842 1854 Email pbaker johnstonboiler com Thom Parker Phone 616 842 5050 ext 314 Fax 616 842 1854 Email tparker johnstonboiler com Rick Slater Phone 616 842 5050 ext 336 Fax 616 842 1854 Email rslater johnstonboiler com Ed Wessel Phone 616 842 5050 ext 311 Fax 616 846 6380
14. acts See individual component manuals for more information on specific component maintenance issues C Maintenance Schedule Johnston Boiler Company recommends the following maintenance schedule for the upkeep of your Johnston burner Any omission form this schedule could cause the Warranty to be voided Only qualified and experienced boiler burner and control personnel should attempt any maintenance and or repair on any boiler ourner Be sure you have read and understood this entire manual before attempting maintenance or repair This maintenance schedule assumes a Johnston burner Refer to your boiler manual for trim and boiler maintenance Daily The following maintenance tasks should be performed daily by the operator 1 Check boiler manual for all items pertaining Check over the boiler and burner for proper operating pressures and temperatures 3 Check the startup and operation of the burner pilot and main flames Check the appearance of the flames for proper and stable combustion Standard electrode setting is 1 8 to 3 16 gap 4 For oil fired burners check the operation of the fuel oil pump heater for heavy oil and air compressor Check the oil level in the compressor Check the condition of the fuel oil strainer for cleanliness 5 Check to make sure that an adequate air supply into the boiler room is being maintained Check to make sure that the inlet screen on the blower assembly is clean and free from obstruction
15. atertube boilers ranging from 1800 to 3000 Boiler Horsepower 62 000 to 100 000 Ibs Steam per hour All Johnston burners are factory test fired when installed on Johnston boilers C Components of the Burner Johnston Series S burners Fig 6 1 consists of a burner plenum assembly and floor mounted blower Blower Produces and controls the Assembly combustion air flow required for the burner Damper Includes blades shafts bearing and linkage arms joints and rods Throttles the amount of combustion air being delivered to the burner Inlet Silencer optional Plenum Box Assembly Access Plate Refractory Sleeve Pilot Assembly Scanner Assembly Oil Gun Assembly Main Gas Ring Spuds or Plugs Swirler Insulated extension to reduce air entrance noise Collects the combustion air and fuel and directs it through the burner Provides for access into burner internals Supports combustion and helps establish aerodynamic flow field The refractory sleeve also protects the boiler tube sheet from high temperature gases and radiation from the flame Provides a flame or high energy spark which is utilized to ignite the fuel at the main burner Standard electrode setting is 1 8 to 3 16 gap Sensor which ensures that pilot and main flame have been established and are proven during all firing conditions Either ultraviolet or infrared depending on application Delivers and mixes the re
16. ccept responsibility for shipping damages or claims against transporters A Parts and Service Policy Johnston Boiler Company markets their products through a distribution system made up of independent manufacturers representatives For parts and service requirements contact your authorized Johnston representative B Parts Warranty Claims and Material Return Johnston Boiler Company s warranty on parts whether purchased as a component part of a new boiler or as a replacement part is as described under the WARRANTY AND EXCLUSION OF IMPLIED WARRANTIES paragraph of Johnston s Standard Terms and Conditions of Sale Johnston s parts warranty claim policy and return procedure is as follows It is recognized that often a warranty replacement part may be needed in advance of returning the claimed defective part for warranty consideration Johnston Boiler Company can accommodate this situation In order for Johnston to advance a warranty replacement part a written purchase order must be issued to Johnston Boiler Company in the amount of the selling price for the replacement part and to cover any prepaid shipping charges that Johnston may incur Upon receipt of the purchase order and subject to availability of the replacement part the advance warranty replacement part will then be shipped in the manner requested At this same time Johnston will issue and submit an invoice covering the part and freight charge Johnston will include a pr
17. d on the boiler burner Emergency Shutdown Procedure Automatic_ Non Recycling No action by the boiler operator is required for an automatic emergency shutdown to occur however the manual emergency shutdown procedure must be followed after an automatic emergency shutdown In this instance the control system extinguishes the flame automatically and will not restart until the problem is corrected Such a shutdown is caused by unsafe conditions such as low water flame failure high steam pressure or water temperature high or low fuel pressure etc and is usually accompanied by an audible or visible alarm Normal Shutdown Procedure Automatic Recycling No action by the boiler operator is required Operating controls signal pressure temperature sensors open automatically The operating control senses Manual the boiler water temperature or steam pressure and shuts down the burner when it has reached the setpoint This is the most 1 Turn the burner switch to OFF position or depress the Burner Off pushbutton if so equipped common shut down and is a normal part of 2 Close all manual fuel valves the burner operation When the water 3 If equipped turn oil pump on off switch to temperature or steam pressure drops the off system will automatically restart the burner 4 Close main blowoff or drain valves 5 Close continuous blowdown stop valve if Manual Drive burner to low fire Turn burner pre
18. de of the boiler whether this is noted to ensure safe and satisfactory operation of the though smell or visible to the eye Prior to light system off the boiler chamber must be purged free of any unburned fuel NOTE The following sequences assume that a Johnston boiler control panel and burner CAUTION management system have been supplied with During initial startup the operator must be on the burner If these items have been supplied by constant alert for conditions such as leaks others the general sequence and intent will be and electrical malfunctions The operator as follows but the control system manufacturer should be constantly aware of the positions will have to be consulted for operational details of manual shutdown valves and switches to ensure fast manual shutdown if necessary WARNING Do not attempt to start up a boiler or burner unless you have read and understand this entire manual Only qualified and experienced boiler burner and controls start up and service personnel should attempt to start any boiler burner Startup Procedure Gas 1 Make sure that all linkages arms and connection points are tight in the fuel air ratio system 2 Ensure that the burner is in gas firing mode with the shifter lever positioned for gas firing 3 Close the main shutoff cock and the supervisor shutoff cock on the main gas train and the manual shutoff cock on the pilot gas train 4 Check the gas supply for the required p
19. e Adjustments Section Oil Pump Pressure Oil Preheat Heavy Oil Only Modulating fuel valve Oil Nozzle Carboned up or plugged Check and clean e Atomizing Air not Sufficient to support Low Fire f Cold oil in Line Heavy Oil Only 20 09m Normally Open Vent Valve not Closed Gas Only a Coil Burned out or Defective Mechanical Part of Valve Inoperable o Checking Cock Closed Gas Open Valve Incorrect Burner Adjustment Gas a Check for proper incoming gas supply to main regulator Check Fire Test Sheet b Check regulated gas pressure Check Fire Test Sheet c Check for slipped or disconnected linkage d Make sure gas control valve is set properly for low fire lightoff PILOT FLAME ESTABLISHED AND PROVEN MAIN FLAME ATTEMPTS TO LIGHT BUT PROGRAMMER CONTROL GOES INTO ALARM CONDITION Momentary Opening of Non Recycling Interlock Circuit Between Terminals 38 P for FireyeE110 and 6 amp 7 for Honeywell RM7800 a Check Combustion Air Switch Should be Closed when Blower Starts b Check Low Oil Pressure Switch when Oil Valves Open Check Oil Pressure Gauge for Momentary Drop of Pressure c Check Low Gas Pressure Switch when Gas Valves Open Check Regulated Gas Pressure Gauge for Momentary Drop of Pressure Section 12 PROBLEM POSSIBLE CAUSE SOLUTION MAIN FLAME NOT STABLE AFTER IGNITION ENDS Incorrect Air Oil Ra
20. e by the arm Firing Rate Modification Firing rate is the rate at which fuel is burned Firing rate is controlled on gas and oil burners by the modulating control valves For burners equipped with a parallel point positioning control system firing rate can be adjusted directly from the boiler programmer See programmer manual for instructions on adjustments For burners equipped with a single point positioning system as seen in figure 6 2 adjustments are made by modifying the linkages from the MOD motor The firing rate can be adjusted on gas burners by adjusting the linkage connection to the control valve To increase the firing rate lengthen the connecting rod to create a great angle between the rod and the linkage To decrease the firing rate shorten the connecting rod to decrease the angle The firing rate on oil burners is modified by adjusting the linkage to the oil control valve This valve is adjusted just like the gas control valve VAN More Dead Travel Less Dead Travel Burner Fires More Slowly Burner Fires More Quickly f Figure 9 4 Fuel Valve Modification Section 9 FGR Percentage Increasing the amount of flue gases that are recycled on an FGR equipped burner will decrease the amount of NOx emissions present in the stack flue gas It will also however decrease the amount of oxygen present in the air entering the combustion chamber Therefore a balance must be reached that minimizes NOx emissions
21. e flue gases Combustibles are a good indication of incomplete combustion Joint farther from pivot Joint closer to pivot e ZAA S N 7 Linkage Rod Figure 9 1 Linkage Joint Adjustment Large Rotational Motion Small Linear Rod Motion Small Rotational Motion Large Linear Rod Motion Figure 9 2 Linkage Arm Modification If oxygen levels are too high too much excess air is being allowed into the combustion chamber High oxygen levels may also cause loud flame vibrations To remedy this adjust the inlet air damper to allow less air in or adjust the fuel control valve to allow more fuel to the flame front If oxygen levels are too low not enough air is being let into the combustion chamber Open the inlet air damper to allow more air in or tune the control valve to allow less fuel to the flame front High Carbon Monoxide levels are an indication of either too much oxygen or not enough oxygen is being introduced to the flame front This must be adjusted using the fuel control valve and the inlet air damper With gas burners at high fire with a proper fuel air ratio the flame should appear blue With a Johnston Lo NOx FGR system the flame should appear dark blue or even a purple color at high fire At high fire on an oil burner the flame should appear bright yellow if a proper fuel to air ratio is achieved x More Dead Travel for Air on Low Fire Dampers Open Slowly Air on Low Fire Dampers Open Quickly
22. e numbered 3 part Return Authorization Tag Exhibit A with any shipment of an advance warranty replacement part This tag must be completed by someone knowledgeable of the claimed defect in the part to be returned The green copy of the tag TO BE RETAINED BY PARTY MAKING RETURN is to be kept by the party making the return The remaining two 2 copies of the tag yellow JBC RECEIVING GIVE TO JBC SERVICE PARTS and buff hard copy ATTACH TO PART BEING RETURNED ALSO TO INCLUDE YELLOW COPY are to be attached to the claimed defective part The part is then to be returned to Johnston Boiler Company freight prepaid collect freight shipments will not be accepted for warranty consideration Upon Johnston s receipt of the claimed defective part the part will be reviewed for warranty consideration A decision to accept or reject the warranty claim will be made On parts that were manufactured by Johnston this decision will be made by Johnston On parts that were purchased by Johnston the claimed defective part will be returned by Johnston to the actual manufacturer of the part to be reviewed for warranty consideration Any such other manufacturer will make the decision to accept or reject the warranty claim Johnston will forward this decision onto its customer the same as Johnston s own decision on warranty claims covering any parts it manufactures Johnston will notify its customer of the decision on a parts warranty claim in writing
23. e of insulation blanket block or mud Attach plenum and transition assemblies via bolts and nuts Attach blower assembly with bolts and nuts Grout and anchor blower assembly to suitable foundation Connect inlet housing damper and finally the silencer Connect or install all other devices as required for your application and purchase DL co 0 YO 0 DA 10 Electrical supply lines should be properly installed to the burner It is recommended that fuel supply lines be properly valved so the supply lines to the burner can be shut off when it is not in use or when preventive maintenance or repairs to the burner are being made A dirt trap should be installed in the gas supply line just prior to entering the main gas train of the burner A means to disconnect and lockout the power supply to the burner control panel should also be provided Installation of burner fuel and electrical power supply piping and lines should be checked so as not to interfere with operation of any component part of the burner or interfere with the ability to perform preventive maintenance or make repair Special attention should be given to making sure that no piping or lines interfere with chamber doors hatches or removable components C Boiler Room Air Supply The starting point in any combustion system is the supply of fresh air To avoid serious problems the boiler must have an adequate supply of fresh air and a supply system that does not affect the bo
24. e personnel should attempt to start any boiler Startup Procedure Combination Fuels In addition to the startup procedure for the fuel to be fired startup for combination fuel burners require the following 1 Set the fuel selector switch on the boiler control panel to the desired position 2 Ensure that the register adjustment arms located on the side of the plenum box are adjusted to the correct position for the fuel to be burned 3 Turn the burner operating mode switch manual auto to the manual mode 4 Turn the firing rate control dial switch potentiometer to its lowest setting low fire 5 Review the startup procedure in the following pages of this manual for the specific fuel gas or oil to be burned 6 Turn the burner switch on With all the recycling limits in the boiler circuitry made the load demand light on the boiler control panel will light The boiler pre purge will now occur The burner modulation MOD motor and linkage will drive the combustion air damper and from its low fire start position to high fire and back to its low fire start position During this process which takes about two minutes more than four air changes will take place in the boiler fireside With the low fire position proven the burner pilot will attempt to light After the pilot has been proven the main fuel valve will open the vent valve between the main fuel valves will close and the main burner will attempt to light for gas Aft
25. e pressure 11 Make sure that the connections of the fuel oil supply and atomizing air hoses or lines inside the plenum box are tight 12 Check motor rotation of the atomizing air compressor Check the oil level in the air compressor Note If shop air plant air is to be used for atomizing air rather than an air compressor supplied with the burner or boiler make sure that the air supply is adequate for the burner need Make sure there is a manual shutoff cock and pressure gauge in the shop air supply line upstream of the pressure regulator A needle valve must also be installed to trim the regulated shop air supply along with a gauge to indicate the regulated and trimmed atomizing air Refer to Fig 7 2 Note In some instances both an air compressor furnished with the boiler and shop air plant air may be available for atomizing air If so the source of the atomizing air must be controlled This is accomplished with manual valves or solenoid valves and a control panel selector switch The motor of some air compressors furnished with the boiler or burner also drives the burner fuel oil pump and motor must be provided and used when shop air is supplying the atomizing air to the burner or the drive belts to the air compressor must be removed Section 9 WARNING Do not attempt to start up a boiler unless you have read and understand this entire manual Only qualified and experienced boiler burner and controls start up and servic
26. ed to control the amount of fuel that enters the burner The most common system installed on boilers is the single point positioning system It employs a single modulation motor that is connected to a shaft that controls the opening and closing of the fuel control valve s and air damper simultaneously There are three ways to adjust the fuel flow ona single point positioning system 1 Adjust linkage joint position This adjustment has the largest effect on firing rates Move the joint between the linkage rod and the linkage arm to a different hole on the linkage arm Doing so will change the linkage arm s radius By moving the joint towards the pivot of the linkage arm a driven linkage arm will increase rotation greatly By moving the joint away from the pivot of the linkage arm a driven linkage arm will decrease rotation If the joint location is moved towards the pivot of a driving arm the rotation of the driving arm will not be affected but the linkage rod will move slower causing the driven arm to rotate slower If the joint is moved away from the pivot of a driving arm the driven arm will move quicker 2 Change the stroke or length of the linkage rods This will change how fast or how slow the modulating firing rate motor changes the fuel or air settings By increasing the amount of dead travel that a linkage arm must go through the firing rate will be slowed down By decreasing the amount of dead travel the firing rate is sped
27. ents consult SEALMASTER Engineers TABLE 1 100 RPM Up to 120 F Clean 6 to 12 Months 500 RPM Up to 150 F Clean 2 to 6 Months 1000 RPM Up to 210 F Clean 2 Weeks to 2 Months 1500 RPM Over 210 F Clean Weekly Any Speed up to 150 F Dirty 1 Week to 1 Month Any Speed Over 150 F Dirty Daily to 2 Weeks Any Speed Any Temp Very Dirty Daily to 2 Weeks Exterme Conditions Daily to 2 Weeks Any Speed Any Temp For normal operating conditions relubricate with a grease conforming to NLGI No 2 Penetration free from chemical impurities such as dust rust metal particles or abrasives Section 10 Boiler Operator Water visible in gauge glass Combustion check visual Steam pressure Feedwater pressure Feedwater temperature Flue gas temperature Burner Supply Gas Pressure Valve Gas Pressure Manifold Gas Pressure Oil Regulated Pressure Oil Nozzle Pressure Oil temperature Atomizing media pressure Flame Signal Blowdown water columns Blowdown boiler Comments Observations JOHNSTON BOILER COMPANY BOILER ROOM LOG Section 11 Parts Service and Warranty Claims NOTE It is the responsibility of the individual company organization or institution receiving a new burner or packaged system to inspect the shipment for damage alteration or missing components upon initial receipt Transporters insist that all deficiencies be noted on the shipping documentation prior to acceptance Johnston will not a
28. er the main burner flame has been established and proven the burner pilot will shut off The boiler and burner operation is now under the command of the boiler and burner programmer 7 Check the low fire hold control aquastat located in the forward lower side of the boiler pressure vessel for the proper setting The minimum setting should be 180 F 8 Set the burner operating mode switch manual auto to the auto position 9 Turn the firing rate control dial switch potentiometer to its maximum setting The burner is now capable of driving from low fire to high fire and anywhere in between as the demand may require but only after the low fire hold control aquastat has been satisfied minimum boiler water temperature of 180 F Section 9 STARTUP SERVICE REPORT The following document should be completed by an authorized service technician at startup and after any adjustments are made A copy of this document must be submitted to Johnston Boiler Company to validate the warranty Model Number Serial Number Startup Date Gas Oil Low Fire Mid Fire High Fire Low Fire Mid Fire High Fire Stack 02 Stack CO2 PPM Stack CO2 Stack NOx PPM Firing Rate CFH GPH Main Flame Signal Combustion Efficiency Blower Wheel Inlet Pressure WC Plenum Box Pressure WC Rear Combustion Chamber Pressure WC Stack Outlet Pressure WC Fuel Supply Pressure Be
29. ffect the stability of combustion due to varying weather conditions wind direction and velocity humidity and temperature Changes in temperature can lead to massive CO production soot formation and unstable unsafe combustion If direct ducting is to be used we suggest the following steps be followed 1 Each boiler has its own completely separate fresh air ducting and exhaust stack to minimize combustion problems 2 Boiler directly connected to fresh outside air ducts must be checked for proper combustion adjustment and operation every three months by a certified package firetube boiler specialist 3 The duct work supplying the fresh air to the boiler must be sized so that it has a maximum pressure drop of 0 05 w c at maximum flow Section 8 4 The fresh air supply should have an electric hot water or steam heater to temper cold outside air to at least 50 deg F 5 If the application is utilizing a low emission with flue gas recirculation do not use direct ducted outside air The potential problems associated with a standard burner are intensified with a low emission burner Section 9 Startup Adjustments and Shutdown A Startup General Startup Information When possible Johnston burners are factory test fired to ensure that components and systems are functional All burners supplied on Johnston boilers are test fired as units to as close to the minimum and maximum firing rates as practical The fuel air ratio is adj
30. fore Main Regulator psi Regulated Fuel Pressure After Main Regulator psi Manifold Gas Pressure WC Oil Pressure at Nozzles psi Atomizing Air Pressure at Nozzles Ues S BEE EOS EEE EEE BEE Ambient Temperature F Stack Temperature F Service Technician Signature Printed Name Date Section 9 B Adjustments General When possible all Johnston burners are fire tested and adjusted before shipment by qualified burner personnel However due to combustion specific variations such as fuel quality air composition and density and operating conditions additional adjustments at the jobsite are often necessary The fine tuning of a burner requires a proper fuel air ratio A proper fuel air ratio is achieved by adjusting both the air flow and the fuel flow Proper fuel air ratio is tested using the make up of the stack gases and the stack temperature Proper stack gases should contain from 3 to 3 5 02 less than 50PPM CO 90PPM for lo NOX burners and 30PPM or less NOX for lo NOX burners Consult factory for proper stack temperature based on your boiler model Swirler Vane Adjustment The vanes of the swirler can be adjusted to allow the correct amount of air through them Adjusting the vanes will also adjust the amount of swirl inflected upon the air that travels through them Controlling Amount of Fuel Flow The control systems used when setting up the burner are design
31. grease chosen for its chemical and mechanical stability SEALMASTER bearings are designed for lubrication with grease Units furnished with a grease fitting should be periodically relubricated The relubrication interval depends on bearing operating conditions speed temperature and environment See Conditions APPROX 1 50 MIS in Table 1 below for typical relubrication ALIGNMENT EACH ___ ALEMITE FITTING schedules SIDE OF CENTER i peed chie f GREASE WHILE Figure 1 shows the annular passage and port RUNNING WHEN LOCKING FIN i m NOTE V GROOVE feature of the SEALMASTER relubricable units POSSIBLE PUMP SLOW 4 podi This feature provides positive means for SLIGHT BEAD FORMS K 8588 SEALMASTER relubrication while allowing several degrees of HERE f me BEARING misalignment If the grease fitting supplied with ZONE VU HARDENING Li AA the unit is replaced make certain the same length of thread engagement is maintained LOCKING PIN FEATURE Fig 1 Relubrication 1 Add grease slowly with shaft rotating until a slight bead forms at the seals 2 Relubrication is generally accompanied by a temporary rise in operating temperature until the bearing chamber is stabilized with the proper amount of grease 3 If necessary to relubricate while bearing is stationary refer to SEALMASTER catalog for maximum grease capacity for the size bearing 4 For abnormal operating conditions of high temperature or abnormal environm
32. he air inlets should be provided with some type of weather protection but should never be covered with a fine mesh wire screen This type of covering results in poor air flow and is subject to clogging by dust dirt paper and other small items To determine the net free open area required for an opening divide the total air required in cubic feet per minute by the allowable velocity at the opening from the table below Acceptable Air Velocities in Boiler Room 0 7 ft above floor 250 feet per minute Above 7 ft above floor 500 feet per minute The minimum opening to the outside should be one square foot Air Ducting In some applications the boiler room is located in a building such that it has no outside walls Many of these applications do not have sufficient excess makeup air in the factory to allow for combustion air requirements In these cases there are two possible solutions 1 Ducting fresh air into the boiler room Where this is required the general rules for the size of the wall opening can be used to determine the size of the ducting and wall opening in the boiler room In addition the pressure drop through the duct must never exceed 0 05 w c 2 Ducting fresh air directly into the boiler This method of air supply should be avoided whenever possible The disadvantages of this type of system far exceed any perceived advantages If used the ducting becomes a part of the boiler system and can a
33. iler operation An adequate proper and consistent supply of fresh air must be supplied into the boiler room for burner combustion air A rule of thumb is to provide four to six square inches of open unrestricted area for every boiler horsepower Example For a 75 HP boiler 300 to 450 square inches of open unrestricted area are recommended How much air is required In general the following formulas have been developed to determine the amount of combustion air required for any boiler room with a package firetube boiler firing gas or oil fuels Section 8 3 Combustion _ Air HP 8 es min HP er ft Ventilation _ Air HP 2 min HP fe Total Air _ Re q HP 10 min HP HP refers to the total maximum boiler horsepower in the boiler room These calculations are adequate for installations up to 1000 feet above sea level For any installation above 1000 fasl add 3 air for each 1000 fasl What size of opening to the outside is required The size of the fresh air inlet openings and their location are very important There should be a minimum of two permanent air supply openings in the walls of the boiler room Whenever possible they should be at opposite sides of the boiler room and no higher than 7 feet above the floor This will promote mixing with the air already in the boiler room proper cooling of the boilers and tempering of potentially colder outside air prior to its entering the burner for combustion T
34. losure switches are closed if present Make sure oil valve proof of closure switches are closed if present Blower Motor Contactor Replace Blower Motor Contactor Defective Blower Motor Defective Replace Blower Motor Flame Safeguard Replace Flame Safeguard Defective Section 12 PROBLEM POSSIBLE CAUSE SOLUTION COMPRESSOR DOES NOT START OIL BURNERS ONLY OIL PUMP DOES NOT START OIL BURNERS ONLY PILOT FLAME IS ESTABLISHED BUT FLAME SAFEGUARD FAILS TO SENSE IT Fuel Selector Switch Move switch to Oil position in Gas Position or Gas On Pushbutton is Depressed Low Compressor Oil Levels Switch is Open Compressor Motor Overload Relay Tripped Close Low Compressor Oil Level Switch if supplied Check setting of overload relay against nameplate FLA Correct any condition causing overload and reset overload relay Compressor Motor Replace Fuses Fuses Blown Compressor Motor Replace Compressor Motor Contactor Contactor Defective Compressor Motor Replace Compressor Motor Defective Oil Pump Switch not on Heavy Fuel Only Oil Pump Motor Overload Relay Tripped Turn Oil Pump Switch on Check setting of overload relay against motor nameplate FLA Correct any condition causing overload and reset overload relay Oil Pump Motor Replace fuses Fuses Blown Oil Pump Motor Replace Oil Pump Motor Contactor Contactor Defective Oil Pump Motor Replace Oil Pump Motor Contact
35. move it back until the burner is adequately tuned If the tip of the oil gun is placed more than 2 inches from the diffuser oil could spray on the diffuser which is to be avoided Section 9 C Shutdown Note If maintenance is to be performed on the boiler burner follow manual procedure for emergency shutdown as described below Shutdown Procedures Within this manual two shutdown conditions are defined as follows Normal Shutdown The flame is extinguished by either the control system automatic or the user manual with the intent that it be restarted within a short time period Such action is not typically associated with a problem and unless otherwise indicated by the control system is not a cause for alarm Warning If a starting failure occurs for any reason combustible fuel gases may fill the furnace and combustion chamber Never attempt to relight the burner under these conditions without first purging the unburned fuel Emergency Shutdown The flame is extinguished by the control system automatic or the user manual and is the result of a system problem or equipment malfunction Under such conditions the burner may not be restarted until the problem has been corrected and the appropriate safety device s have been reset The manual emergency shutdown procedure should also be followed for extended idle periods where automatic restarting is not required and at any time that maintenance is to be performe
36. o admit gas to the main Shutoff burner but only after a pilot has Valves been proven Electrically actuated and equipped with a proof of closure switch If required Vent Valve Electric normally open valve closes when energized when req d Relieves pressure between normally closed valves Supervisor Downstream shutoff cock Shutoff Cock between main gas valve and flow control valve Manually opens and closes the gas supply to the main burner Control Valve Controls the amount of regulated gas supply pressure to the main burner Valve is controlled by the burner management system Burner Indicates the gas supply Pressure pressure to the main burner Gauge High Gas Permissive Contacts open Pressure under a high gas supply Switch pressure condition Will not allow the burner to operate in high gas pressure conditions Note Gas supply for pilot should be upstream of main shutoff cock Certain main gas supply regulators require this connection to be downstream Check piping schematics for correct connection Section 7 MODO SY AJOSIASIANS Y dA VA J 4 TSN JA IVA 440 LNHS SY Fig 7 1 JA VA 33015 1 033 33 Ig MOO 18 180 IN TVA LINJA NIYA JANSSJAd 4909 440 LNHS 43010HS IDUId GL SSadd Main and Pilot Gas Trains Section 7 B Atomizing Air Air Pressurizes air to be used in the atomization of oil Not present if shop air plant air is to Compressor be
37. o the main burner but only after a pilot has been proven Electrically actuated If the flame signal drops off the oil valve will shut to insure proper safe combustion May be equipped with a proof of closure switch depending on insurance code requirements Throttles the amount of regulated fuel oil supply to the main burner from low to high fire D Heavy Oil Fuel Oil Preheaters Heat Trace Oil Solenoid Valve Heavy Oil Only Temperature Control Valve Temperature Switch Steam Regulator Steam Trap Additional equipment provided for heavy oils Electric and or Steam Used to heat heavy No 4 thru No 6 fuel oils tallow and waste oil An electric preheater is a thermostatically controlled low watt density preheater for cold oil starting A permissive low oil temperature switch is built in to prevent starting on a low temperature condition A steam preheater is an indirect steam heater with a capacity to heat the fuel oil from approximately 100 F to 230 F A steam preheater is used to heat heavy oils once the boiler reaches its normal operating steam pressure When used in combination fuel burners the electric heater is used as a trim heater maintaining a constant supply temperature Permits the circulation of hot oil in the fuel oil supply system during boiler burner off periods This is done to keep the oil in the line hot for good atomization and flow during burner operation Regula
38. on of a Johnston S style burner Refer to Section 6 to familiarize yourself with parts and terminology It is strongly recommended that a qualified field service technician familiar with Johnston products be present to supervise or do the work These burners will be heavy and unlikely to be lifted by hand You will need appropriate lifting equipment such as fork lifts cranes or cherry pickers to position the burner in place Local Code requirements must also be followed These legal requirements take precedence over information found in this manual B Installation Recommendations Your Johnston S style burner will be shipped in multiple pieces and will need to be field assembled at installation If your burner arrives fully pre assembled it will need to be partially broken down prior to installation The following steps are for reference only and may be altered skipped or rearranged on the basis of field advice for your application 1 If not done so break down burner into multiple pieces A The refractory sleeve B The plenum and blower transition blower inlet housing w damper and silencer This requires removal of nuts bolts and all interconnecting wire linkage tubing and pipe 2 Install gasket on refractory sleeve mounting flange if shipped loose Insert refractory sleeve into furnace opening plumb level and attach nuts and washers If excess space between the firing tube and furnace opening exists fill the gap with a refractory typ
39. or Defective Pilot Flame is too Increase Gas Pressure for Larger Flame Small Scanner Tube not Properly Aligned Cracked or Dirty Scanner Lens Re align Scanner Tube Clean or Replace Scanner Lens Check Operation with a Candle or Lighter Faulty Flame Scanner Section 12 PROBLEM POSSIBLE CAUSE SOLUTION BLOWER STARTS BUT SHUTS DOWN AFTER APPROXIMATELY 10 SECONDS AND FLAME SAFEGUARD GOES INTO LOCKOUT BLOWER STARTS BUT AFTER 10 MINUTES OF PURGE FLAME SAFEGUARD GOES INTO LOCKOUT Non Recycling Limit Circuit Open Between terminals 3 8 P for Fireye E110 or terminals 6 amp 7 for Honeywell RM7800 High Fire Purge Limit not Made Between Terminals D amp 8 for Fireye E110 or 5 8 19 for Honeywell RM7800 Combustion Air Switch Open Auxiliary Low Water Cutoff Open Manual reset may be required May not be present on all boilers High Limit Pressure or Temperature Switch Open Manual reset may be required High Gas Pressure Switch Open Manual reset may be required Gas Burners Only Low Gas Pressure Switch Open Manual reset may be required Gas Burners Only Low Oil Pressure Switch Open Oil Burners Only Low Oil Temperature Switch Open Heavy Oil Burners Only High Oil Temperature Switch Open Heavy Oil Burners Only Low Atomizing Air Pressure Switch Open Oil Burners Only Blower Motor Contactor Auxilia
40. quired amount of oil and atomizing air primary air to the burner at the point of combustion for oil firing Small A series burners have one oil nozzle while large A series burners have three individual oil nozzles Integral with refractory sleeve Delivers the required amount of gas to be burned and distributes the gas at the point of combustion Used to establish good mixing of the gas and combustion air at the burner front Controls the mixing of combustion air with the fuel at the burner front Section 6 Assembly Drawing of an S Burner OVER x FLAME SIGHT PORT DIL NOZZLE ASSE BLOWER TRANSITION COMBUSTION AIR FAN BLOWER PA DAMPER y ASSEMBLY INLET HOUSING FIG 6 1 Section 6 Jackshaft and Transfers movement from firing Burner Trim Components Fig 6 2 Linkage Set rate motor to fuel valves and air dampers Firing Rate Electric Motor to rotate jackshaft Motor on signal to increase or decrease Combustion Permissive Electric pressure burner firing rate Air Switch switch to prove presence of amp combustion air Ignition High voltage transformer when Transformer energized ignites pilot fuel Purge Air Permissive Electric pressure Switch switch to prove the presents of Flame Electronically recognizes the air during burner purge cycle Scanner presence of flame Pilot Normally natural gas or propane Interrupted small flame to ignite main flame Section 6
41. ration Credit Warranty Replacement Credit Warranty Replacement Already Received Reason for Return Exhibit A Section 12 Troubleshooting Johnston Burner with Johnston Boiler PROBLEM POSSIBLE CAUSE SOLUTION BLOWER DOES NOT Zero or Improper Power Check incoming power supply Phase to START Supply Voltage phase voltage should match that which is shown on wiring diagram Check disconnect switch if provided Zero Voltage Between Check control transformer primary and Flame Safeguard Power secondary fuses Replace if blown Supply Terminals Make sure secondary voltage is near Should be 115V 115V Replace transformer if voltage is wrong Recycling Limit Circuit Check voltage between recycling input Open and neutral Voltage should be 115 V Burner switch Burner On relay Gas On relay or Oil On relay open Applicable switch on contact must be closed Operating Pressure or Temperature switch open Low water cut off open Customer interlock not made Any controls added to the recycling limit in the field must be made Blower Motor Overload Check setting of overload relay against motor Relay Tripped nameplate FLA Correct any condition causing overload and reset overload relay Blower Motor Fuses Replace fuses Blown Pre Ignition Interlock a Check voltage between pre ignition Circuit Open interlock input and neutral Voltage should be 115 Make sure gas valve proof of c
42. ressure Make sure that the supply line has been bled Make sure that a dirt trap has been installed in the supply line just before it connects up to the boiler main gas train 5 Install the regulated and manifold gas pressure gauges at their proper location in the main gas train Very often the regulated pressure gauge is a higher range gauge than the manifold pressure gauge 6 Purge the boiler with the pilot gas valve and main gas train valves closed Once the purge is done check visually for a pilot spark Make sure that the scanner does not sense the spark 7 Open the pilot gas shutoff cock slowly 8 Adjust the main gas train regulator to optimize pilot flame refer to flame safeguard manufacturer for proper signals 9 With the downstream second checking shutoff cock closed slowly open the upstream first manual shutoff valve Do not confuse supply or regulated lockup pressures as the result of closed downstream valves or shutoff cocks with continuous flow operating pressures Continuous flow operating pressure will only be accurate when the boiler is operating 10 When initially starting a boiler after a pilot flame has been established slowly open the downstream second checking cock as the main gas shutoff valves open Section 9 11 Check low fire regulated gas pressure against the reading shown on the test fire report located in following pages of this manual The low fire regulated gas pressure should be the
43. ry Contact Open Any other Controls in the Non Recycling Limit Circuit may be open Check the Wiring Diagram for controls not mentioned above If Firing Rate Motor does not Drive to High Fire Position a Check 24V Power Supply From Transformer b Check for Binding Linkage c Check for Faulty Firing Rate Motor If Firing Rate Motor does Drive to High Fire a Check for Faulty or Improperly Adjusted High Fire End Switch inside Firing Rate Motor b Check if the Purge Air Pressure Switch is Open if supplied Note Run Check switch on flame safeguard must be in the run position for the startup sequence to proceed Section 12 PROBLEM POSSIBLE CAUSE SOLUTION HIGH FIRE PURGE IS Low Fire Start Limit Check for Faulty or Improperly Adjusted COMPLETED AND not Made Low Fire End Switch inside Firing Rate FIRING RATE MOTOR RETURNS TO LOW FIRE WAITS 10 MINUTES AND FLAME SAFEGUARD GOES INTO LOCKOUT Between Terminals M amp D for Fireye E110 or 5 amp 18 for Honeywell RM7800 Motor Note Run Check switch on flame safeguard must be in the run position for the startup sequence to proceed PURGE IS COMPLETED AND IGNITION ON LIGHT TURNS ON BUT NO PILOT FLAME IS ESTABLISHED Faulty Flame Safeguard Check for 115V between safeguard ignition terminal and neutral 5 amp L2 for Fireye E110 firing light oil or gas 6 amp L2 for Fireye E110 firing heavy oil 8 amp
44. same as shown on the test fire report CAUTION Every potential operating situation or system condition cannot be foreseen or documented The following instructions should be used as a commissioning guideline by competent and experienced burner service technicians Specific situations may mandate deviations based on sound judgment and engineering experience Consult the Johnston Burner factory if questions or problems are present Startup Procedure Oil 1 Check that all linkages are in working order 2 Ensure that the burner is in oil firing mode with the shifter lever positioned for oil firing 3 Check for a manual shutoff valve in the fuel oil supply line upstream of the fuel oil strainer Make sure that this shutoff valve is open 4 Check to see that the fuel oil strainer is clean 5 Check to make sure that the fuel oil supply storage tank has an adequate supply of fuel oil in it 6 Check motor rotation on the fuel oil pump Make certain that the fuel oil supply to the pump does not exceed the maximum pump inlet pressure 7 Make sure that there is no shutoff valve in the fuel oil supply return line 8 Bleed off any air that may have accumulated in the electric oil preheater 9 Ensure that the manual shutoff valve in the tracer line is open Heavy Oil Only 10 Make sure that the drain valve in the fuel oil supply line to the burner oil gun is closed drain also used for gauge fitting to check burner oil gun nozzl
45. sent at facility switch to OFF position Some control 6 Close main feedwater and chemical feed panels may have a Burner Off pushbutton inlet valves if present at facility which must be depressed rather than a 7 Close hot water valves or steam stop selector type switch valve s if present at facility 8 Lock out incoming power according to plant specifications at main disconnect panel necessary if work is to be performed on unit 9 Do not attempt to reverse these actions or to restart the burner until the problem s has been identified and corrected Section 9 D Flue gas analysis Boiler flue gas analysis is used to determine combustion efficiency Carbon Dioxide CO2 Carbon Monoxide CO Indicates complete combustion Indicates incomplete combustion Oxygen 02 Indicates the presence of excess air Oxides of Nitrogen NOx A product of high temperature combustion Combustibles Material that burns when exposed to oxygen and heat It is typical to target oxygen levels of 8 in low fire and 3 in high fire for gas fired burners It is typical to target oxygen levels of 6 in low fire and 4 in high fire for oil fired burners Johnston Boiler Company recommends no greater level than 200 ppm of Carbon Monoxide in its burner operation The acceptable Industry Standard level is 400 ppm or less Johnston Boiler Company recommends zero combustibles for a gas
46. terials specific to this job A thorough understanding of and familiarity with these documents is required prior to systems installation commissioning operation or trouble shooting Pre Startup Checks Burner a The electrical power supply has been run to the control panel A disconnect has been installed at the control panel just before the power supply enters the control panel If the control panel was supplied by others ensure that it is wired to match the wiring diagrams that came with your burner a All motor rotations have been checked blower oil pump air compressor against the direction of rotation labeled on the motor Due to job specific differences in motor setup proper motor rotation is labeled by the factory using arrows a There is nothing about the installation that will no longer allow the burner and fuel train s to operate properly and be adjusted as may be necessary Fuel supply pressures match the specification sheet Continuity and electrical check of any wiring that was required into the control panel For oil firing fuel oil has been circulated and strainers are empty and clean Section 9 NOTE ian WARNING Do not attempt to light or re light the pilot or Commissioning or adjustment of the Johnston main burner of any boiler on any fuel if the Burner must be made by factory authorized presence of an excess amount of fuel is noted in technicians and experienced service technicians the firesi
47. tes steam flow to heater on the basis of oil temperature entering the heater Permissive switch control circuit on temperature of oil interrupts high Supplied when boiler operating pressure exceeds 150 psig Collects and discharge condensate from steam heater Section 7 Special Notes a Most burners utilize a gas pilot ignition whether the main burner operates on gas or oil b Atomizing air in some instances atomizing steam is used to burn all fuel oils in Johnston burners Atomizing air can be supplied by an air compressor furnished by Johnston Boiler Company with the burner or by shop air plant air available in the boiler room If shop air is to be used an air regulator must be present to maintain constant air pressure c Oil pilot sometimes referred to as a diesel ignition uses No 2 oil for pilot flame Fuel Train Figure 7 3 Typical 2 Oil Train Section 7 Fuel Train a GATE CHECK REGULATOR F COVER 150 PSD THERMOMETER STRAINER DIL PUMP AND MOTOR SET BACK PRESS REGULATOR SAFETY SHUTOFF VALVE SAFETY SHUTOFF VALVE _ ELECTRIC THEATER PRESSURE TEMPERATURE RELIEF SWITCH PRESSURE SWITCH HEAT TRACE AND GAUGE LOOP SOLENOID CONTRO VALVE Fig 7 4 Typical Heavy Oil Train Section 8 Field Installation If not factory installed A General Information The following are general recommendations for assembly and installati
48. tio Oil Firing See Adjustments Section for Adjustment Procedure a b h Check for slipped or disconnected linkage Make sure Oil Control Valve is set properly Check for Proper Oil Pressure to Oil Nozzle Check for Belt Slippage on Compressor or Oil Pump Check for Proper Oil Temperature to Nozzle Heavy Oil Check for Suction Leak on Suction Line Creating Air Pockets in Oil Supply Check for Water in Oil Supply Suction Line should be 6 or more off Bottom of Tank Check for Dirty Oil Strainer Incorrect Air Gas Ratio Gas Firing See Adjustments Section for Adjustment Procedure a b Check for slipped or disconnected linkage Make sure gas control valve is set properly Check for dirt or pipe scale in Main Regulator Make sure that a dirt leg is in ahead of regulator or a strainer Check for ruptured diaphragm in regulator Check for a plugged vent line on regulator Make sure regulator external sensing line if applicable is installed correctly Make sure normally open vent valve between safety shutoff gas valves closes tight when safety shutoff gas valves are energized SAFETY SHUTOFF VALVE S DO NOT SHUT OFF WHEN OPERATING LIMITS OPEN Safety Shutoff Valve s Mechanically Stuck Open Check for obstructions and manually close valve Section 12 PROBLEM POSSIBLE CAUSE SOLUTION MAIN FLAME LIGHTS IGNITION IS OFF BUT FIRING R
49. used Typical air pressures range up to 100 psi Air Regulator Controls fluctuations in the air pressure from shop air plant air line Not present if air compressor is used Air Tank Dampens pulsations from air compressor Air Switch Permissive Low air pressure disables electrical control circuit Section 7 Atomizing Air COMPRESSOR AIR FILTER CH amp GUARD BELT ATOR AIR SWI GUL RE CH SWIT GAUGE AIR if DIL GUN Fig 7 2 Section 7 C Light Oil Inlet Strainer Oil Pump Oil Regulator Low Oil Pressure Switch Safety Shutoff Valves Flow Control Valve Filters out any foreign matter in the fuel oil supply Increases the pressure of the fuel oil supply to the required pressure See oil pump manual for exact inlet pressure ratings Caution Some pumps will leak through shaft seal if rated inlet pressure is exceeded A back supply pressure regulator that maintains constant oil pressure to the flow control valve Excess oil is recirculated back to a tank or the pump inlet The set pressure is a function of firing rate and required nozzle pressure Typical supply pressures to nozzles are 40 80 psig for Delevan nozzles and 50 100 psig for Monarch nozzles Not always supplied may be integral to pump Opens undera low oil pressure condition allow the burner under this condition supply Will not to operate Open to admit oil t
50. usted as much as possible with the factory conditions Because each field application is unique due to flue stack configurations fuel composition variations elevation and other variables the final burner setup and calibration must be conducted after system installation by a qualified burner service technician Contact your Johnston Boiler Representative or the Johnston Boiler factory service department for scheduling and rates of factory authorized commissioning assistance Burners supplied as stand alone items will not be fire tested Where the word boiler is used it will be synonymous with chamber or other device to which the burner is applied Pre Startup Checks Boiler or Applicable Chamber Note If your Johnston burner is to be installed on an apparatus not made by Johnston Boiler Company follow the startup procedure given by the manufacturer of the product a The boiler chamber is properly installed on a concrete pad grouted and is level a The flue stack has been installed A rain cap has been installed if directly connected to the flue gas outlet a The boiler chamber s piping blowoff blowdown and feedwater systems have all been installed and connected according to the manufacturer s instructions a The boiler chamber s doors and access openings are fully accessible NOTE Each Johnston burner is shipped with an order specification sheet bills of material piping diagram wiring diagram and other reference ma
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