IC-SA-1714 MTH Series Manual 11-2012
Contents
1. Installation INDUSTRIAL COMBUSTION Burner Model Boiler HP A 25 60 18 35 83 20 42 100 22 52 125 20 63 150 22 84 200 30 105 250 30 126 300 30 147 350 32 160 380 32 FIGURE 2 2 Burner Model Boiler HP 2 5 Installation The burner is designed for operation with the blast tube level Do not tilt the burner up or excessively downward Securely support the burner pedestal on the floor or foundation Allow enough clearance at the rear of the burner to allow the housing to swing open for service and maintenance Many boilers including some Scotch Marine types do not have sufficiently rigid front plates and reguire additional support under the burner base Bases under the support leg must be long enough to support the burner when being inserted or withdrawn from the boiler Boilers operating with the combustion pressure above atmospheric pressure must be sealed to prevent escape of combustion products into the boiler room The burner mounting flange is designed to provide for a seal The face of the boiler and burner flange must be sealed IC SA 1714 11 2012 2 3 MTH Series Manual Installation INDUSTRIAL COMBUSTION with a rope gasket not supplied with the burner Make sure the dry oven and burner blast tube are concentric For maximum safety it is recommended that boilers not op2. INDUSTRIAL COMBUSTION MTH Series Table of Contents Introduction 1 1 1 1 Overview 1 1 1 2 Description 1 1 1 3 Operating Controls 1 2 1 3 1 Control Panel 1 2 1 3 2 Flame Safeguard Controls 1 2 1 3 3 Firing Rate Controls 1 2 1 4 Combustion Air Handling System 1 3 1 5 Firing Head 1 3 1 6 Gas System 1 4 1 6 1 Main Gas Train Components 1 4 1 6 2 Pilot Gas Train Components 1 6 1 6 3 Operation 1 6 Installation 2 1 2 1 Application 2 1 2 2 Draft Conditions 2 1 2 3 Combustion Air Supply 2 1 2 4 Combustion Chamber Recommendations 2 2 2 5 Installation 2 3 2 6 Packaging Plastic Refractory Around Oven If Dry Oven is Supplied 4 2 7 Gas Piping 2 4 CHAPTER 1 CHAPTER 2 IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION 2 8 Installation Checklist 2 5 Operation 3 1 3 1 Preparations for Starting 3 1 3 1 1 Firing Preparations for Gas Burners 3 2 3 1 2 Burner Settings 3 2 3 1 3 Combustion Settings 3 2 3 1 4 Test Eguipment 3 2 3 2 Electrical Interference Test 3 3 3 2 1 Gas Fired 3 3 3 3 Gas Pilot Flame Adjustment 3 3 3 4 Startup Seguence 3 3 3 5 Automatic Shutdown 3 4 3 6 Manual Shutdown 3 4 3 7 Safety Shutdown 3 4 3 8 Startup and Operating 3 5 3 8 1 Gas Burners 3 5 3 9 Normal Operation 3 6 3 10 Shutdown 3 6 Adjustments 4 1 4 1
3. Center line to main gas inlet L 8 5 8 9 1 4 12 1 2 Mounting flange to main gas inlet E 9 1 4 12 1 4 15 1 4 Diameter of dry oven INDUSTRIAL COMBUSTION MTH Series Spare Parts List Part Number 132 02861 000 132 02825 000 Part Description Burner Size HEAD BURNER MESH 2 5 MMBTU HEAD BURNER MESH 3 5 MMBTU FILTER AIR 14 ID X 19 625 OD ELECTRODE ASSY 0 438 DRAWER ASSEMBLY ELECTRODE WLDMT DRAWER ASSEMBLY TUBE SCANNER SIGHT THERMOCOUPLE 332 00050 000 435 00560 000 435 00531 000 090 04461 000 496 00131 000 132 02862 000 132 02863 000 132 02796 000 332 00050 000 435 00561 000 435 00529 000 090 04392 000 496 00131 000 HEAD BURNER MESH 4 2 MMBTU HEAD BURNER MESH 5 3 MMBTU HEAD BURNER MESH 6 3 MMBTU FILTER AIR 14 ID 19 625 OD ELECTRODE ASSY 0 438 DRAWER ASSEMBLY ELECTRODE WLDMT DRAWER ASSEMBLY TUBE SCANNER SIGHT THERMOCOUPLE 132 02864 000 HEAD BURNER MESH 8 4 MMBTU HEAD BURNER MESH 10 5 MMBTU 132 02865 000 HEAD BURNER MESH 12 6 MMBTU 132 02866 000 HEAD BURNER MESH 14 7 MMBTU 132 02799 000 132 02867 000 332 00060 000 435 00547 000 435 00527 000 090 04407 000 496 00131 000 HEAD BURNER MESH 16 0 MMBTU FILTER AIR 19 ID 23 OD X 14 HGT ELECTRODE ASSY 0 438 DRAWER ASSEMBLY ELECTRODE WLDMT DRAWER ASSEMBLY TUBE SCANNER SIGHT THERMOCOUPLE
4. 5 5 Air Filter Inspection The air filter needs to be inspected daily and replaced on an as needed basis 5 2 IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION Maintenance 5 6 Pilot and lgnition Electrode ELECTRODE WELDMENT ALIGNMENT INDICATOR MARK FOR IGNITOR TUBE ELECTRODE WELDMENT GAS PILOT PIPE NOZZLE INDICATOR PIN ELECTRODE BUSHING ELECTRODE FIGURE 5 1 Pilot Electrode Orientation FIGURE 5 2 Pilot Electrode Gap The ignition transformer reguires little attention other than making sure the ignition wire is firmly attached to the transformer and the electrode Be sure the wire insulation is in good condition and not grounded Failure to keep the ignition electrode clean and properly set can cause faulty operation The pilot assembly is supported by a socket in the diffuser and gas inlet tube No adjustment is reguired except proper positioning of the electrode wire 5 7 Flame Scanner The scanner must be clean Even a small amount of contamination will reduce the flame signal Wipe the scanner lens with a clean soft cloth IC SA 1714 11 2012 MTH Series Manual Maintenance INDUSTRIAL COMBUSTION 5 8 Firing Rate Controls Make sure all connections are tight Adjust if necessary Perform a combustion test as explained in Chapter 4 and readjust the burner if necessary 5 9 Burner Mounting Inspection The seal between the burner flang
5. INDUSTRIAL COMBUSTION HIGH GAS N LOW GAS PRESSURE PRESSURE SWITCH MAIN GAS SWITCH e VALVE W P 0 C M MAIN TEST REGULATOR GAS 4 OPENING BUTTERFLY SHUTOFF VALVE T SHUTOFF a VALVE COCK SI TYPICAL COCK TO s mt mEm84 8057 El H LA PILOT SHUTOFF COCK O TO E BURNER lv PILOT REGULATOR VALVE FIGURE 1 2 Main Gas Train MTH 25 to MTH 105 HIGH GAS LOW CAS PRESSURE PRESSURE A SWITCH SWITCH N F 14 4 H T TEST BUTTERFLY SHUTOFF SHUTOFF VALVE it a Bh a n T 41 4 N 7 a yt NEN TEH O HE d H 4 PILOT VENT MAIN GAS REGULATOR SHUTO VALVE CAS VALVE 5 VALVE W P 0 C TO S S BURNER IL PILOT REGULATOR VALVE FIGURE 1 3 Main Gas Train MTH 126 to MTH 160 NOTE These piping layouts are for reference only and are subject to change witho
6. N 5 5 IC SA 1714 11 2012 3 5 MTH Series Manual Operation INDUSTRIAL COMBUSTION 10 Do not repeat unsuccessful light off attempts without rechecking burner and pilot adjustment Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt 11 Set the gas low fire rate by adjusting the gas butterfly valve and air valve 12 When low fire is adjusted shut down the burner 13 Restart several times to be sure the low fire setting is suitable Readjust if necessary Never start the burner with fuel vapor in the furnace In case of an emergency open the main power switches and close all fuel valves 14 After combustion adjustments are satisfactorily set allow the heating vessel to slowly reach normal operating pressure or temperature 15 Turn the potentiometer switch to the high fire position Check high fire at this point using combustion instruments 16 Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate settings High fire combustion analysis typically is 7 to 8 O When conditions covered above are assured refer to Sections 3 9 and 3 10 3 9 Normal Operation Normal operation must be with the MANUAL AUTO switch set AUTO In automatic operation the operating cycle always proceeds sequentially through pre purge pilot ignition main flame ignition run and post purge T
7. Overview 4 1 4 2 Combustion Adjustment on Gas 4 1 4 2 1 Stack Temperature 4 1 4 2 2 Gas Adjustments 4 2 4 3 Electrical Interference Test 2 4 4 Gas System 4 2 4 4 1 Gas Pressure 4 2 4 4 2 Gas Flow 4 2 IC SA 1714 11 2012 MTH Series Manual CHAPTER 3 CHAPTER 4 INDUSTRIAL COMBUSTION 4 4 3 Gas Pilot Flame Adjustment 4 2 4 4 4 Main Gas Pressure Regulator 4 3 4 4 5 Low Gas Pressure Switch 4 3 4 4 6 High Gas Pressure Switch 4 3 4 4 7 Gas Combustion Adjustment 4 3 4 5 Parallel Positioning Adjustment 4 4 Maintenance 5 1 5 1 Overview 5 1 5 2 Control System 5 1 5 2 1 Programming Control 5 2 5 8 Impeller and Inlet Cone 5 2 5 4 Firing Head Inspection 5 2 5 5 Air Filter Inspection 5 2 5 6 Pilot and lgnition Electrode 5 3 5 7 Flame Scanner 5 3 5 8 Firing Rate Controls 5 4 5 9 Burner Mounting Inspection 5 4 5 10 Gas System 5 4 5 10 1 Motorized Main Gas Valves 5 4 5 10 2 Solenoid Valves 5 4 5 11 Electrical System 4 5 11 1 Electric Motors 5 5 5 12 Extended Shutdown 5 5 5 13 Recommended Maintenance Schedule 5 6 lii CHAPTER 5 IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION CHAPTER 6 Troubleshooting 6 1 6 1 Awareness 6 1 6 2 Emergency Shutdown 6 2 6 3 Problem Possible Causes 6 3 STARTUP SERVICE REPORT WARRANTY POLICY IC SA 1714 11 20
8. size of the pilot flame obtain a proper DC volt or microamp reading of the flame signal 4 2 IC SA 1714 11 2012 MTH Series Manual Adjustments INDUSTRIAL COMBUSTION The flame safeguard amplifier has a meter jack for this purpose At initial startup and during planned maintenance test the pilot flame signal pilot turndown and safety switch lockout An ultra violet flame sensor electrical spark interference test must be performed after final adjustment See Section 4 3 of this chapter for additional information 4 4 4 Main Gas Pressure Regulator The gas pressure reguired at the burner manifold is the pressure that is reguired to fire the burner at its rated capacity The gas pressure regulator must be adjusted to achieve this pressure to assure full input Refer to manufacturer s literature for regulator adjustment 4 4 5 Low Gas Pressure Switch Turn adjusting screw until indicator moves to a pressure setting slightly below the operating gas pressure The control will break a circuit if pressure is below this set point The control should be finally adjusted to prevent operation with low gas pressure but not at a pressure so close to normal operating pressure that unnecessary shutdowns occur The switch must be manually reset after tripping To reset allow gas pressure to rise and press the manual reset button 4 4 6 High Gas Pressure Switch Turn the adjusting screw until the indicator moves to a pressu
9. the burner or burner related eguipment N Caution It is important that you provide support for the housing when in the open position to prevent damage to the hinges and other components A maintenance program avoids unnecessary down time costly repairs and promotes safety It is recommended that a record be maintained of daily weekly monthly and yearly maintenance activities Electrical and mechanical devices reguire systematic and periodic inspection and maintenance Any automatic features do not relieve the operator from responsibility but rather free him from certain repetitive chores providing time for upkeep and maintenance Unusual noise improper gauge reading leak sign of overheating etc can indicate a developing malfunction reguiring corrective action 5 2 Control System Most operating controls reguire very little maintenance beyond regular inspection Examine electrical connections Keep the controls clean Remove any dust from the interior of the control Covers should be left on controls at all times Keep the control cabinet doors closed Dust and dirt can damage motor starters and relay contacts Starter contacts are plated with silver and are not harmed by discoloration Never use files or abrasive materials such as sandpaper on contact points IC SA 1714 11 2012 5 1 MTH Series Manual Maintenance INDUSTRIAL COMBUSTION 5 2 1 Programming Control This control reguires no
10. trial with just the electrical ignition system energized the flame relay should not pull in be energized 3 Upon completion of successful test proceed with startup procedures 4 Reconnect the power supply and proceed with startup procedures 4 4 Gas System 4 4 1 Gas Pressure Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas train and furnace pressure while running at full input Refer to nameplate inside control panel for gas pressure requirements at train inlet and manifold The pressures listed are based on nominal 1000 Btu cu ft natural gas at elevations up to 2000 feet above sea level 4 4 2 Gas Flow The volume of gas is measured in cubic feet as determined by a meter reading The gas flow rate required depends on the heating value Btu cu ft The supplying utility can provide this information as well as pressure correction factors To determine the required number of cubic feet per hour of gas divide burner input Btu hr by the heating value Btu cu ft NOTE When checking the input rate Make sure no other equipment is operating on the same meter 4 4 3 Gas Pilot Flame Adjustment The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator Normal setting is 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame Although it is possible to visibly adjust the
11. which a burner operates must be supplied with adeguate fresh air for combustion and ventilation purposes Fresh air supply must meet or exceed all code reguirements Consult with insurance carrier and or local authorities for specific regulations A Warning The boiler room pressure must be at least egual to the outdoor atmospheric pressure Where fan ventilation is used air must be forced into the boiler room Never exhaust air from the boiler room Adjoining areas having exhaust fans must be positively isolated from the boiler room IC SA 1714 11 2012 2 1 MTH Series Manual Installation INDUSTRIAL COMBUSTION 2 4 Combustion Chamber Recommendations The combustion chamber dimensions should be adeguately sized to prevent flame impingements C MIN Combustion Chamber Min Length in 45 IC SA 1714 11 2012 MTH Series Manual Combustion Chamber Min Width in 18 20 BLOCK INSULATION Z lt gt 0505050505 RSI lt lt gt gt x LSI x RRIK 4 5 os RSS STANDARD FIREBRICK X e a 1 1 2 A Burner Size 25 6 14 8 5 23 5 50 0 9 0 29 2 35 6 14 8 5 23 5 50 0 9 0 29 2 23 9 23 9 3 375 3 375 67 8 67 8 30 5 30 5 11 5 11 5 FIGURE 2 1 Combustion Chamber Dimensions
12. 1 5 115 230 1 42 8 27 3 52 3 27 3 63 3 27 3 MTH 84 4 MTH 105 4 MTH 126 4 MTH 147 4 14 700 350 20 6 1 5 3 0 460 3 MTH 160 4 16 000 380 20 6 1 5 3 5 460 3 NOTES 1 Gas input based on natural gas at 1 000 Btu cu ft and 0 60 gravity 2 Gas pressure based on O w c furnace pressure For total pressure at manifold add furnace pressure 3 Boiler overall efficiency of 80 estimated Blower wheel and motor HP is based on altitude up to 2 000 ft above sea level For higher altitude or 50 Hz applications consult factory 5 Firing at higher furnace pressures de rates the burner by approximately 5 per 1 2 of additional pressure Consult factory INDUSTRIAL OMBUSTION 0 e MTH Series Standard Dimensions Accompanying dimensions are for layout purposes only Burner Frame Size 8 Model Number Overall burner length J 88 3 4 106 3 4 137 4 Length of element 0 38 3 8 49 1 4 70 Mounting flange to panel 57 1 2 67 3 4 Center line to right side T 17 1 8 17 3 4 23 Center line to left side K 23 7 8 24 1 2 26 1 4 Center line to top A 31 1 4 29 3 4 44 Center line to bottom P 23 1 2 27 1 4 30 1 2 Mounting flange to hinge B 18 1 2 21 1 2 24 1 2 Center line to hinge 8 5 8 9 1 4 12 1 2 Length of suppor 33 8 Width of support R 23 1 2 27 1 4 30 1 2 Mounting flange to support 29 1 4 34 3 4 23 7 8 20 1 2 circle diameter 1812
13. 12 MTH Series Manual INDUSTRIAL COMBUSTION CHAPTER 1 Introduction 1 1 Overview MTH series burners are completely assembled wired and tested at the factory N Caution Only factory authorized burner service personnel should start up adjust or service this eguipment AA Warning Burner air fuel metering valves and positioning motors have not been pre set by the factory for proper combustion and must be set by a gualified and authorized technician Failure to follow this procedure could result in property damage and personal injury The operator must be familiar with the individual functioning of all controls to understand the operations and procedures described in this manual 1 2 Description The MTH series are gas only pre mix type burners All burners feature ignition by spark ignited gas pilot flame The burner operates with full modulation A switch permits changeover from automatic fully modulated firing to manually set firing at any desired rate between minimum and maximum Additional safeguards assure that the burner always returns to the minimum firing position for ignition MTH series burners are designed for automatic unattended operation except for periodic inspection and maintenance After selecting the proper overload settings for the starter the rest of the control panel components reguire little attention except for occasional cleaning IC SA 1714 11 2012 1 1 MTH Series Ma
14. MIH SERIES Installation Operation and Service Manual INDUSTRIAL COMBUSTION A WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SERVICE THIS EQUIPMENT IC SA 1714 11 2012 INDUSTRIAL COMBUSTION MTH SERIES Installation Operation and Service Manual Manual Number IC SA 1714 Release Date November 2012 Information to be filled out by owner Unit Serial Number Date of Installation Distributor Information Name Address Phone Number INDUSTRIAL COMBUSTION Copyright O 2012 by Industrial Combustion All rights reserved No part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means without the prior written consent of Industrial Combustion Industrial Combustion 351 21st Street Monroe WI 53566 608 325 3141 ind comb com INDUSTRIAL COMBUSTION It is the responsibility of the owner of this eguipment to post and maintain a legible copy of this Installation Operation and Maintenance manual while this eguipment is in service Warning and caution references have been made in this manual and should be adhered to for smooth operation of the burner A Warning This symbol precedes information which if disregarded may result in injury to the user of the burner or to others N Caution This symbol precedes information which if disregarded may result in damage
15. adjusting the pressure setting of the pilot regulator Normal setting is 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame Although it is possible to visibly adjust the size of the pilot flame obtain a proper DC volt or microamp reading of the flame signal Refer to Flame Safeguard manufacturers instructions for optimal flame signal readings The flame safeguard amplifier has a meter jack for this purpose At initial startup and during planned maintenance test the pilot flame signal pilot turndown and safety switch lockout 3 4 Startup Seguence The programming control seguences the operation of all controls and components through the starting ignition firing and shutdown cycle The burner and control system are in starting condition when The operating and high limit control temperature or pressure are below their cutoff setting All power supply switches are closed e Power is present at the control panel Refer to the manufacturer s literature on programming controls and burner wiring diagrams for detailed information 1 Begin starting seguence with burner switch off and with all manual valves closed Switch main power on 2 Open the main manual gas valve IC SA 1714 11 2012 3 3 MTH Series Manual Operation INDUSTRIAL COMBUSTION 3 Manually reset the high and low gas pressure switches 4 When the burner motor start
16. adjustment nor should any attempt be made to alter contact settings or timing logic Those programmers with contacts may require occasional cleaning If so follow instructions given in the manufacturer s bulletin Never use abrasive materials The manufacturer s bulletin also contains troubleshooting information The flame detector lens should be cleaned as often as conditions demand A periodic safety check procedure should be established to test the complete safeguard system Tests should verify safety shutdown with a safety lock out upon failure to ignite the pilot or the main flame and upon loss of flame Each of these conditions should be checked on a scheduled basis The safety check procedures are contained in the manufacturer s bulletin 5 3 Impeller and Inlet Cone Proper clearance between the impeller and the inlet housing set at 3 8 nominal Adjust the inlet cone so it is centered in the inlet of the impeller and tighten the bolts There should be no contact between the inlet cone and the impeller Inserting a bar through the impeller blade and using it as a lever will only damage the blade and also void the impeller warranty 5 4 Firing Head Inspection Release the impeller housing latches and swing the housing open for access to the firing head Inspect the flame scanner lens to be sure it is clean Inspect the lead wire to the ignition electrode It must be firmly attached and the insulation should be clean and free of cracks
17. air fuel ratios at all rates must be determined by combustion analysis See Section 4 2 of this chapter for additional information NOTE Check for CO through the entire firing range 4 5 Parallel Positioning Adjustment For parallel positioning systems refer to the control manufacturer s documentation and to the accompanying wiring diagram for information on adjusting the system In a properly tuned parallel positioning system the independent actuators for fuel and air will be coordinated to provide optimum combustion throughout the firing range Normally the air control damper will be approximately 1 open in low fire position Excessive opening in low fire can cause pilot ignition problems Air to the pilot is supplied under pressure to compensate for variations in furnace pressure but the damper must be in low fire position for reliable ignition A Warning Keep fingers away from the air intake below the damper The damper is actuated with sufficient force to cause severe injury 4 4 IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION CHAPTER 5 Maintenance 5 1 Overview A Warning Any cover plates enclosures or guards anchored to the burner or any burner related equipment must remain in position at all times Only during maintenance and service shutdown can these cover plates enclosures or guards be removed They must be replaced and securely anchored before testing adjusting or running
18. aking preliminary settings The proper settings of air fuel ratios must be determined by flue gas analysis Combustion gas analysis indicates the air to fuel ratio and the degree of complete combustion Instruments are available to measure carbon dioxide CO oxygen O and carbon monoxide 4 2 1 Stack Temperature Net stack temperature is obtained by subtracting the ambient temperature from the flue gas temperature A high net stack temperature indicates wasted heat Stack temperature should be as low as possible without causing flue gas condensation Stack heat loss can be reduced by decreasing either the temperature or the volume of the flue gas or both Flue gas temperature is reduced by improving heat transfer or by reducing excess combustion air A certain amount of excess air is necessary to complete combustion More efficient burners reguire minimum excess air IC SA 1714 11 2012 4 1 MTH Series Manual Adjustments INDUSTRIAL COMBUSTION 4 2 2 Gas Adjustments Low fire combustion analysis typically is 7 to 9 O and less than 04 CO 400 ppm A high fire reading typically is 7 to 8 O and less than 04 CO 4 3 Electrical Interference Test Prior to putting the burner into service conduct the following test to ascertain that ignition spark will not cause the flame relay to pull in Gas Fired Test 1 Close the pilot and main line manual gas valves 2 Start the burner and at time of pilot
19. ameplate inside the control panel for minimum and maximum fuel input ratings 3 1 4 Test Eguipment The following tests should be conducted on site 1 Combustion analyzer with O indication 2 U Tube manometer or pressure gauge to measure gas pressures Main and Pilot 3 Inclined manometer to measure draft pressures 4 CO analyzer 5 Voltmeter Ammeter 6 Stack thermometer and thermocouple A Warning Should a starting failure occur for any reason combustible fumes may fill the combustion chamber Never attempt to re light the burner under these conditions without first purging the chamber 3 2 IC SA 1714 11 2012 MTH Series Manual Operation INDUSTRIAL COMBUSTION Read the flame safeguard manual and fully understand its content before attempting to operate this eguipment If this instruction is ignored serious injury or death may result 3 2 Electrical Interference Test Prior to putting the burner into service conduct the following test to ascertain that the ignition spark will not cause the flame relay to pull in 3 2 1 Gas Fired 1 Close the pilot and the main line manual gas valves 2 Start the burner and at the time of the pilot trial with just the electrical ignition system energized the flame relay should not pull in be energized 3 Upon completion of successful test proceed with startup procedures 3 3 Gas Pilot Flame Adjustment The gas pilot flame is regulated by
20. as shown in the manufacturer s flame safeguard manual A Warning Read the flame safeguard manual and fully understand its contents before attempting to operate this eguipment Failure to do so may result in serious personal injury or death 1 3 3 Firing Rate Controls Regardless of the fuel used burner input is fully modulated between low fire and high fire on boiler demand The firing rate is controlled by the parallel positioning control system The combustion air control damper and or gas butterfly valve are controlled by actuators The actuator rotates 90 from low to high position 1 2 IC SA 1714 11 2012 MTH Series Manual Introduction INDUSTRIAL COMBUSTION 1 4 Combustion Air Handling System The combustion air handling system consists of three major components Component Damper Assembly A rotary damper regulates the combustion air volume and is positioned by a modulating motor The damper is normally almost closed in the low fire position and opens as the burner drives toward a high fire position Motor Driven Impeller The diameter of the impeller determines available air pressure and the width determines air capacity in cubic feet per minute Alternate motor impeller combinations are available for 50 cycle or 60 cycle power and for firing against either moderate or high furnace pressure All standard impellers are sized for up to 2 000 ft altitudes and up to 6 W C furnac
21. burner Make certain that the operator in charge is properly instructed in the operation and maintenance procedures N Caution Before opening the gas shutoff valves read the regulator instructions carefully Open the shutoff valve slowly to allow inlet pressure to build up slowly in the regulator until it is fully pressurized Opening the shutoff valve guickly will damage the regulator Do not exceed the regulator pressure ratings IC SA 1714 11 2012 2 5 MTH Series Manual Installation IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION 2 6 INDUSTRIAL COMBUSTION Operation CHAPTER 3 3 1 Preparations for Starting When the installation is complete and all electrical fuel water and vent stack connections are made make certain said connections are tight The operator should become familiar with the burner boiler controls and components To identify controls and components refer to contents of Chapter 1 Adjustment procedures given in Chapter 4 should be reviewed prior to firing The wiring diagram should also be studied along with the operating seguence of burner programmer Read and understand starting instructions before attempting to operate the burner Before attempting to start the burner the following checks must be made 3 1 Check Check the boiler water level Be sure all boiler valves are installed correctly and positioned properly Set the high limit con
22. d other parts and components not manufactured by the Company are warranted only to the extent of and by the original manufacturer s warranty to the Company In no event shall such other manufacturer s warranty create any more extensive warranty obligations of the Company to the Buyer than the Company s warranty covering eguipment manufactured by the Company Exclusions From Warranty I THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES ORAL OR EXPRESS OR IMPLIED INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION OF THE EQUIPMENT THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE CONTAINED HEREIN TO THE EXTENT PERMITTED BY THE LAW THERE ARE NO IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE THE PROVISIONS AS TO DURATION WARRANTY ADJUSTMENT AND LIMITATION OF LIABILITY SHALL BE THE SAME FOR BOTH IMPLIED WARRANTIES IF ANY AND EXPRESSED WARRANTIES II The Company s warranty is solely as stated in a above and does not apply or extend for example to expendable item ordinary wear and tear altered units units repaired by persons not expressly approved by the Company materials not of the Company s manufacture or damage caused by accident the elements abuse misuse temporary heat overloading or by erosive or corrosive substances or by the alien presence of oil grease scale deposits or other contaminants in the equipment Warranty Adjustment Buyer must make claim of any breach of any warranty by written notice to the Compa
23. e and furnace front plate must not permit combustion gases to escape Periodic inspection is important Replace the gasket if necessary Inspect the burner head for signs of discoloration A change the head color paint might indicate gas leakage between the burner flange and the boiler refractory If leakage occurs refer to Chapter 2 Section 2 4 for proper sealing procedure 5 10 Gas System N Caution Disconnect all power before servicing the valves 5 10 1 Motorized Main Gas Valves Should the valve fail to operate check for voltage at the valve Make certain that the main shutoff cock is closed prior to testing The actuator is not field repairable nor should it be disassembled Replace the actuator if the valve fails to operate After replacement cycle the valve with the fuel shutoff to determine that it opens and closes If the valve has a visual indicator observe its position for correct operation 5 10 2 Solenoid Valves A slight hum from the solenoid is normal when the coil is energized Should the valve fail to operate check that there is voltage at the valve coil If there is no voltage at coil check for loose wiring connections If there is proper voltage at the valve coil and the valve still fails to open replace the coil Refer to manufacturer s bulletin for correct procedure in coil replacement Should it become necessary to replace the complete valve be sure that the flow is in the direction of the arrow o
24. e pressure setting recorded On combination fuel models set the selector switch to the desired fuel On initial startup it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through pre purge and pilot sequences to determine that the main gas valve opens Turn the burner switch OFF and let the programmer finish its cycle Check to see that the gas valve closes tightly Set the high and low gas pressure switches Check for leaks and determine there is adeguate gas pressure available at the burner for operating at full capacity Check with the local utility if necessary Check gas pressure at the pilot and the main burner Close the manual gas valve 3 1 2 Burner Settings To ensure reliable and safe burner performance the air damper blade must be adjusted relative to the established flow rates to provide the correct amount of air for complete efficient combustion The damper blade is not preset at the factory and must be checked prior to placing the burner into initial service or after conducting any service work that may have altered its position 3 1 3 Combustion Settings Fuel and air flow rates are individually adjusted at low fire and at high fire to achieve rated heat input firing rate turndown optimum efficiency safe operation and the ability to cope with environmental changes including air temperature humidity barometric pressure and fuel property changes Refer to the n
25. e pressures Alternate impeller wheels are available For higher altitudes and higher furnace pressures motor and impeller combinations are determined at the factory Air Filter 99 Removal efficiency to two microns 1 5 Firing Head Access to the firing head is provided by swinging open the impeller housing An internal gas pilot is standard on all burners Pilot gas pressure is adjusted at the pilot pressure regulator SCANNER WIRES ELECTRODE CABLE BURNER HOUSING MAIN GAS INLET GAS PILOT INLET FIGURE 1 1 Burner Housing IC SA 1714 11 2012 1 3 MTH Series Manual Introduction INDUSTRIAL COMBUSTION 1 6 Gas System Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold The firing rate is regulated by a rotary butterfly type throttling valve at the manifold inlet The valve is actuated by the actuator Depending upon specific reguirements one or two safety shutoff motorized main gas valves are provided for installation in the gas train upstream of the butterfly valve Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating seguence 1 6 1 Main Gas Train Components Depending upon the reguirements of the regulating authority the gas control system and gas train may consist of some or all of the following items Component Description Gas Volume Valve The b
26. erating under pressure should also be sealed 2 6 Packing Plastic Refractory Around Oven If Dry Oven is Supplied N Caution It is important that you provide support for the housing when in the open position to prevent damage to the hinges and subseguent components The area between the outside circumference of the dry oven and existing refractory should be packed with Kaiser Refractory Mono T 9 Airset or egual within two hours after coating the dry oven with Trowleze From inside the furnace ram the plastic refractory from the front to the rear parallel to the outside surface of the dry oven 2 7 Gas Piping Refer to Figures 1 2 and 1 3 for typical gas piping schematics Gas service and house piping must supply the guantity of gas demanded by the unit at the pressure reguired at the burner gas train inlet All piping must be in strict accordance with applicable codes ordinances and regulations of the supplying utility In the absence of other codes piping should be in accordance with the following standards National Fuel Gas Code NFPA No 54 ANSI No 2 223 1 for Canada the Canadian Gas Association CGA B149 and Canadian Standards Association CSA B140 codes shall prevail Gas train components upstream of the butterfly valve are shipped loose These components should be mounted by the installer as close to the butterfly valve as practical Normally the control train is ordered to suit a particular code or insura
27. fuel valves 3 If the burner operates in a damp environment cover it with plastic to protect all electrical components from moisture Remove the flame safeguard control and store in a dry atmosphere IC SA 1714 11 2012 5 5 MTH Series Manual Maintenance INDUSTRIAL COMBUSTION 5 13 Recommended Maintenance Schedule Item Service By Remarks DAILY Gauges Monitors Indicators Operator Make visual inspection and record readings in log Instrument amp Equipment Settings Operator Make visual check against recommended specifications Low Water Fuel Cutoff amp Alarms Operator Refer to instructions Air Filter Operator Refer to instructions WEEKLY Firing Rate Control Operator Verify factory settings Igniter Operator Make visual inspection Check flame signal strength Pilot amp Main Fuel Valves Operator Open limit switch Make audible and visual check Check valve position indicators and check fuel meters Flame Failure Controls Operator Close manual fuel supply for 1 pilot and 2 main fuel cock and or valve s Check safety shutdown timing Record in log Flame Signal Strength Controls Operator Read and log the flame signal for both pilot and main flame Notify Service if readings are very high very low or fluctuating MONTHLY Low Fan Pressure Interlock Operator Manually adjust until switch opens High amp Low Gas Pressure Operator Refer to instructions Manually adjust until switch opens Interloc
28. he length of the purge and ignition trial vary according to the type of programmer used During the run cycle burner input is regulated to the load demand by the modulating pressure or temperature control on the boiler The burner will continue to modulate until the operating pressure or temperature is reached Programmer control operation should be tested when the burner is initially placed into service when a control is replaced and at scheduled intervals in the maintenance program Refer to adjustment procedures and maintenance instruction given in Chapters 4 and 5 3 10 Shutdown When the operating limit control setting is reached or the burner switch is in the OFF position the following seguence occurs 1 The fuel valve s de energize and the flame extinguishes The blower motor continues running during post purge 2 At the end of post purge the blower motor is de energized 3 The programmer returns to its starting position and stops The unit is ready to restart 3 6 IC SA 1714 11 2012 MTH Series Manual Operation INDUSTRIAL COMBUSTION Abnormal shutdown might result from motor overload flame outage low water current or fuel supply interruption combustion air pressure below minimum level tripped circuit breakers blown fuses or other interlock devices Check for the cause and make the necessary corrections before restarting the burner Safety shutdown caused by ignition or flame failure will act
29. installation or use of the eguipment IC SA 1714 11 2012 MTH Series Manual
30. ks Scanner Operator Check inspect and clean for soot buildup Pilot Assembly Operator Check for loosening of components erosion or carbon buildup ANNUALLY Impeller Operator Inspect and clean the combustion impeller Combustion Test Service Tech Perform a complete combustion test Adjust burner if necessary Read and log data Pilot Turndown Test Service Tech Required after any adjustment to flame scanner or pilot adjustment Operating Controls Service Tech Refer to instructions 5 6 IC SA 1714 11 2012 MTH Series Manual Set Point N A N A Startup Service Report The following information should be filled in by the service technician at startup or after any adjustment to the burner A copy of the startup report MUST be forwarded to IC in order to validate the warranty of the burner Control Check Low Water Cutoff Aux LWCO High Water Cutoff Operating Limit High Limit Operating Control Test Stack Temp Interlock Flame Failure Combustion Air Switch High Purge Switch Low Fire Interlock Oil Pressure Switch N A Oil Valve w P O C Interlock MA High Gas Pressure Switch Low Gas Pressure Switch Gas Valve Interlock Pilot Turndown Test Flame Signal Pilot For Low NOx Burners Blast Tube Temp Interlock FGR Line Purge Switch FGR Valve Startup Date Amperage 50 High Serial Number Voltage Burner M
31. losed to prove proper gas pressure A normally open vent valve if required is located between the two automatic gas valves This valve is shut when the automatic gas valves are open When the automatic valves are closed the vent valve is open for venting gas to the outside should any be present 1 6 IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION CHAPTER 2 Installation 2 1 Application Electrical power available is usually 208 volt 3 phase 60 cycle 230 460 volt 3 phase 60 cycle or 380 volt 3 phase 50 cycle Control circuit is 115 volt single phase 60 cycle or 115 volt single phase 50 cycle Refer to the electrical schematic diagram shipped with the burner Power connections are made at the control panel Wiring from the panel to burner mounted components is installed at the factory Wiring from the burner panel to boiler controls low water controls remote compressor motor and remotely located fuel valves is furnished by the installer 2 2 Draft Conditions Automatic over fire draft control or barometric draft regulators are not usually reguired except where the system has a tall chimney The exact height of a chimney reguiring draft control is indeterminate but draft regulation is seldom needed for chimneys less than fifty feet high especially with Scotch Marine or sealed firebox boilers Gas piping instructions are described in this Chapter 2 3 Combustion Air Supply The space in
32. n the body Test for gas leaks and check valve action several times to ensure proper operation before attempting to relight the burner 5 11 Electrical System Because of the many types of flame safeguard systems applicable to this eguipment complete descriptions of all burner electrical systems are beyond the scope of this manual An individual electrical schematic drawing is shipped with each burner and complete operation and troubleshooting instructions are available from the various flame safeguard system manufacturers 5 4 IC SA 1714 11 2012 MTH Series Manual Maintenance INDUSTRIAL COMBUSTION 5 11 1 Electric Motors Motor supply voltage must not vary more than 10 percent from nameplate ratings At initial startup and at least once a year thereafter check the motor current with a meter while the burner is in high fire position If the reading exceeds the nameplate rating plus service factor determine the cause and correct it immediately In dusty locations clean the motor regularly to assure adeguate cooling Lubricate in accordance with the manufacturer s instructions 5 12 Extended Shutdown When shutting down the burner for an extended period of time the operator should use the following general guidelines to protect the burner from its surrounding elements This will add to the operating life of the burner 1 Turn the main electrical disconnect switch to the burner to OFF 2 Close all main
33. nce regulation such as Underwriters Laboratories Inc CGA or Factory Mutual Arrange gas piping at the burner so that the burner is accessible for servicing without disassembly The gas pilot supply line must be connected upstream of the main gas regulator If a reducing bushing is required between the house piping and the burner piping it should be close to the burner shut off valve The gas piping must be internally clean and free of foreign material Before using in service a leak test must be performed 9 4 IC SA 1714 11 2012 MTH Series Manual Installation INDUSTRIAL COMBUSTION 2 8 Installation Checklist All burners are carefully assembled and tested at the factory but before being placed in service all connectors should again be checked for looseness caused during shipment Check e Electrical terminals in the control panel and on all electrical components Pipe fittings and unions Tubing connections e Nuts bolts screws Before connecting electrical current to any component be sure the supply voltage is the same as that specified on component nameplates Before burner operation be sure all motors are rotating in the correct direction Before firing make sure that the burner mounting flange is properly sealed to the boiler front plate It is the installers responsibility to identify the main electrical power disconnect and the manual shut off valve on the gas supply drop line to the
34. nual Introduction INDUSTRIAL COMBUSTION 1 3 Operating Controls 1 3 1 Control Panel The control panel contains a flame safeguard programming control motor starters relays time delays and terminal strips mounted internally on a panel sub base Lights switches potentiometers a control circuit breaker and flame safeguard displays are mounted externally on the panel Component Details Control Circuit Breaker Supplementary low overcurrent protection only No larger than 15 amps Auto Manual Modulation a Auto Position Selects boiler modulation control Selector Switch b Manual Position Selects manual potentiometer for modulating control Manual Modulating Control Increases or decreases the burner firing rate manually Signal Lamps a POWER ON white Illuminates when the control circuit is energized powered b IGNITION amber Illuminates when the ignition transformer is powered and the pilot valve is energized opened MAIN VALVE green Illuminates when the main fuel valve or valves gas or oil are energized open d FLAME FAILURE red Illuminates when the flame safeguard system fails to detect pilot or main flame 1 3 2 Flame Safeguard Controls The flame safeguard programmer incorporates a flame sensing cell Scanner to shut down the burner in the event of pilot flame or main flame failure Other safety controls shut down the burner based on sequence of operation
35. ny s home office within thirty 30 days of the discovery of any defect The Company agrees at its option to repair or replace BUT NOT INSTALL F 0 B Company s plant any part or parts of the equipment which within twelve 12 months from the date of initial operation but no more than eighteen 18 months from date of shipment shall prove the Company s satisfaction including return to the Company s plant transportation prepaid for inspection if required by the Company to be defective within the above warranty Any warranty adjustments made by the Company shall not extend the initial warranty period set forth above Expenses incurred by Buyer in replacing or repairing or returning the equipment or any part or parts will not be reimbursed by the Company Spare and Replacement Parts Warranty Adjustment The Company sells spare and replacement parts This subparagraph 10 4 is the warranty adjustment for such parts Buyer must make claim of any breach of any spare or replacement parts by written notice to the Company s home office within thirty 80 days of the discovery of any alleged defect for all such parts manufactured by the company The Company agrees at its option to repair or replace BUT NOT INSTALL F O B Company s plant any part or parts or material it manufacture which within one 1 year from the date of shipment shall prove to Company s satisfaction including return to the Company s plant transportation prepaid for inspection if requi
36. odel Electric Motors Control Voltage Blower Motor Air Compressor Air Oil or Metering Test Conducted Firing Rate MMBtu gph Stack Temp gross Room Temp 02 Smoke Bacharach Combustion Eff Stack Draft W C Furnace Pressure W C Blast Tube Pressure W C Steam Pressure PSIG Water Temp F Supply Oil Pressure PSIG Return Oil Pressure PSIG Vacuum Oil Pump HG Oil Temp Atom Air Pressure Inner Manifold Outer Manifold Gas Pressure Burner Manifold W C Center Gas Pressure W C Gas Pressure Regulator Inlet PSIG Gas Pressure Regulator Outlet PSIG Pilot Gas Pressure Regulator Outlet W C Low Flame Signal Main Adjusted by Date Accepted by Signature Required INDUSTRIAL COMBUSTION IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION Warranty Policy Limited Warranty The Company warrants that at the time of shipment the eguipment manufactured by it shall be merchantable free from defects in material and workmanship and shall possess the characteristics represented in writing by the Company The Company s warranty is conditioned upon the eguipment being properly installed and maintained and operated within the eguipment s capacity under normal load conditions with competent supervised operators Eguipment accessories an
37. re setting slightly above the maximum operating gas pressure The control will break a circuit if pressure exceeds this value The control should be adjusted to prevent operation with excessive gas pressure but not at a pressure so close to normal operating pressure that unnecessary shutdowns occur This switch must be manually reset after tripping To reset allow gas pressure to drop and press the manual reset button 4 4 7 Gas Combustion Adjustment After operating for a sufficient period of time to assure a warm boiler make adjustments for most efficient combustion The butterfly gas valve directly controls the rate of flow The low fire light off setting should be regarded as preliminary until proper gas pressure for high fire operation is established Determine the actual gas flow from a meter reading at high fire With the butterfly valve open and with regulated gas pressure set the actual flow rate should be quite close to the required input If corrections are necessary increase or decrease the gas pressure by adjusting the gas pressure regulator following manufacturer s directions for regulator adjustment When proper gas flow is obtained take a flue gas analysis reading With the high fire air fuel ratio established the gas pressure regulator needs no further adjusting Recheck low fire and adjust if necessary IC SA 1714 11 2012 4 3 MTH Series Manual Adjustments INDUSTRIAL COMBUSTION Proper setting of the
38. red by the Company to be defective within this part warranty The warranty and warranty period for spare and replacement parts not manufactured by the company purchased by the Company from third party suppliers shall be limited to the warranty and warranty adjustment extended to the Company by the original manufacturer of such parts In no event shall such other manufacturer s warranty create any more IC SA 1714 11 20112 MTH Series Manual INDUSTRIAL COMBUSTION extensive warranty obligations of the Company to the Buyer for such parts than the Company s warranty adjustment covering part manufactured by the Company as set forth in this subparagraph 10 4 Expenses incurred by Buyer in replacing or repairing or returning the spare or replacement parts will not be reimbursed by the Company Limitation of Liability The above warranty adjustment set forth Buyer s exclusive remedy and the extent of the Company s liability for breach of implied if any and express warranties representations instructions or defects from any cause in connection with the sale or use of the eguipment THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEOUENTIAL DAMAGES OR FOR LOSS DAMAGE OR EXPENSE DIRECTLY OR INDIRECTLY ARISING FROM THE USE OF THE EQUIPMENT OR FROM ANY OTHER CAUSE WHETHER BASED ON WARRANTY EXPRESS OR IMPLIED OR TORT OR CONTRACT and regardless of any advice or recommendations that may have been rendered concerning the purchase
39. s open the gas cock 5 When the main fuel lamp lights indicating pilot flame proven slowly open the second shutoff cock downstream of the main gas valve s Refer to the manufacturer s literature on primary control sequence of operations 3 5 Automatic Shutdown Limit or operating controls open 1 Fuel valves close Main fuel lamp goes off Flame safeguard timer starts 2 Flame safeguard timer and burner motor stop Burner is ready for startup on the next call for heat 3 6 Manual Shutdown 1 When the burner motor stops close all manual valves 3 7 Safety Shutdown 1 If at any time during the operating cycle a flame failure occurs the burner shuts down as in Automatic Shutdown with an additional post purge and the flame failure lamp is energized A Warning Read the Flame Safeguard manual and fully understand its contents before attempting to operate this eguipment If the manual is not read and understood serious personal injury or death may result A Warning Should a starting failure occur for any reason combustible fumes may fill the combustion chamber Never attempt to re light the burner under these conditions The combustion chamber must first be purged before re lighting A Warning Keep fingers away from the combustion air intake below the damper The damper is actuated with sufficient force to cause severe injury Always make high and intermediate rate adjustments when the b
40. sistance connections The relay chassis is mounted on the sub base with a screw which when tightened completes the connection between the sub base and chassis contacts Press the manual reset button to be sure safety switch contacts are closed Check the control actuator for proper movement of the air volume damper and fuel metering components Check the air shutter and adjust low fire setting IC SA 1714 11 2012 3 7 MTH Series Manual Operation IC SA 1714 11 2012 MTH Series Manual INDUSTRIAL COMBUSTION 3 8 INDUSTRIAL COMBUSTION CHAPTER 4 Adjustments 4 1 Overview While each burner is tested at the factory for correct operation before shipment variable conditions such as burning characteristics of the fuel used and operating load conditions may require further adjustment after installation to assure maximum operating efficiency Prior to placing the boiler into initial service a complete inspection should be made of all controls connecting piping wiring and all fastenings such as nuts bolts and setscrews to be sure that no damage or misadjustments occurred during shipping and installation A combustion efficiency analysis made during the initial start up will help to determine what additional adjustments are required in a particular installation 4 2 Combustion Adjustment on Gas Efficient combustion cannot be properly judged by flame appearance although it may help in m
41. to the burner NOTE This symbol precedes information which is vital to the operation or maintenance of the burner Model designations are based on the type of fuel s to be fired and the amount of furnace pressure to be overcome Burner size is based on firing rate rated input in Btu hr Model Standards Fuel Air Atomization MTH Gas The eguipment must be installed in accordance with applicable local state or Provincial Installation Requirements including the National Electrical Code NEC and Associated Insurance Underwriters Where applicable the eguipment shall be installed in accordance with the Provincial Installation Reguirements or in their absence the Canadian Gas Association CGA B149 1 and B149 2 and Canadian Standard Association CSA B140 and B139 for oil burners Installation Codes shall prevail Authorities having jurisdiction should be consulted before installations are made Oil and gas burning eguipment shall be connected to flues having sufficient draft at all times to assure safe and proper operation of the burner The MTH Series burners are designed to burn gas only as defined by ASTM 0396 2010 specifications INDUSTRIAL COMBUSTION Standard MTH Series Specifications Min Gas Furnace i Pressure Burner Frame Gas Input Pressure i Reguired Blower Motor Model Size MBtu hr Eff w c in PSI Volt Ph 60 Hz MTH 25 2 2 500 2 1 0 115 230 1 MTH 35 2 3 500
42. trol slightly above the desired temperature Set modulating controls at the desired temperature or pressure Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and the control circuit Check the direction or rotation of the motors Open the housing to check the electrode setting Check the gas pilot pressure at the pilot gas regulator The normal setting is 6 W C For protection in shipment the flame safeguard control chassis is shipped unmounted Check all screw connections before attaching the flame safeguard chassis to the base The screw must be secure to assure low resistance connections The relay chassis is mounted on the sub base with a screw which when tightened completes the connection between the sub base and chassis contacts Press the manual reset button to be sure safety switch contacts are closed Check the control actuator for proper movement of the air volume damper and fuel metering components Check the air shutter and adjust low fire setting Boiler Burner IC SA 1714 11 2012 MTH Series Manual Operation INDUSTRIAL COMBUSTION 3 1 1 Firing Preparations for Gas Burners A representative of the gas utility should turn on the gas Determine by a test gauge upstream of the burner regulator that sufficient pressure exists at the entrance to the gas train The gas pressure regulator must be adjusted to the pressure reguired and th
43. uate a red indicator light and energize an audible alarm if so equipped If the programmer has a non recycling interlock circuit any interruption in this circuit during the pre purge or firing cycle will cause a safety shutdown This type of shutdown requires manual reset of the programming control and must be corrected before operation can be resumed An ultraviolet flame sensor electrical spark interference test must be performed after final adjustment See Section 3 2 in this chapter for additional information Read and understand starting instructions before attempting to operate the burner Before attempting to start the burner the following checks must be made Item Check Boiler Check the boiler water level Be sure all boiler valves are installed correctly and positioned properly Set the high limit control slightly above the desired temperature Set modulating controls at the desired temperature or pressure Burner Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and the control circuit Check the direction or rotation of the motors Open the housing to check the electrode setting Check the gas pilot pressure at the pilot gas regulator The normal setting is 6 W C For protection in shipment the flame safeguard control chassis is shipped unmounted Check all screw connections before attaching the flame safeguard chassis to the base The screw must be secure to assure low re
44. ure must be performed only by authorized and qualified personnel Close the main and pilot gas cocks Make sure the ON OFF switch is in the OFF position and the fuel selector switch is turned to GAS Actuate the manual reset button of the flame safeguard control to close the safety switch contacts Set the MANUAL AUTO switch in the MANUAL position Set the manual potentiometer in the low fire position Open the gas pilot cock Set the ON OFF switch to ON The burner will start and pre purge After pre purge the ignition transformer and the gas pilot solenoid are energized Before proceeding conduct electrical interference and pilot turndown tests if not previously done see Section 3 2 8 On initial startup it is recommended that the main gas shutoff cock remains closed until the programmer has cycled through pre purge and pilot sequence Then determine that the main gas valve opens When this is confirmed turn the burner switch OFF and let the programmer finish its cycle 9 Check to see that the gas valve has closed tightly If ignition does not occur turn the burner switch OFF and allow the programmer to recycle for a new ignition trial Turn the burner ON and after pilot ignition when the flame relay pulls in the slow opening motorized main gas valve is energized The main flame should ignite at this time The gas valve and air damper continue advancing until high fire is reached
45. urner has reached low fire position Do not disturb the low fire setting 3 4 IC SA 1714 11 2012 Series Manual Operation INDUSTRIAL COMBUSTION A The lockout switch on the flame safeguard control must be manually reset before the burner will fire again 2 If alow water condition occurs the burner shuts down as in Automatic Shutdown If a high or low gas pressure condition occurs while firing on gas the burner shuts down as in Automatic Shutdown A Condition must be corrected and the respective gas pressure switch manually reset before the burner will fire again on gas 3 8 Startup and Operating 3 8 1 Gas Burners A gas valve leak test Bubble Test must be performed on the automatic safety shutoff valves located in the main gas train prior to any initial commissioning or subsequent maintenance of the burner and gas train systems where automatic valve proving systems interlocked with the main burner safety control are not provided This test should be performed periodically to ensure no leakage of valves in their closed or de energized position refer to valve manufacturers procedures The unit should be taken out of service if the unit fails any part of the gas valve leak test Any defective part must be replaced prior to putting the equipment back into service Failure to follow this startup procedure may result in explosion fire property damage and personal injury This proced
46. ut notice Optional equipment may change a layout IC SA 1714 11 2012 MTH Series Manual Introduction INDUSTRIAL COMBUSTION 1 6 2 Pilot Gas Train Components Component Description Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to the pilot It closes after main flame is established Gas Pressure Regulator Reduces gas pressure to that reguired by the pilot Gas Pilot Shutoff Cock For manually closing the pilot gas supply 1 6 3 Operation Metered gas flows through the main gas shutoff cock through the pressure regulator to the automatic gas valves and butterfly valve to the gas manifold The butterfly gas valve modulates flow to burner input demand The butterfly valve is positioned through the actuator The air control damper is positioned simultaneously by the actuator and controlled by the parallel positioning control system The automatic gas valve s cannot be energized unless the combustion air proving switch is closed The low and high gas pressure switches must be c
47. utterfly type valve is positioned by linkage from the modulating motor and controls the rate of flow of the gas Main Gas Valves Electrically operated safety shutoff valve s that open to admit gas to the burner Standard U L burners include e Models MTH25 42 One motorized gas valve w POC e Models MTH52 105 One motorized gas valve w POC and one solenoid valve e Models MTH126 147 One dual motorized gas valve w POC Main Gas Regulator Regulates gas train pressure to specified pressure reguired at inlet to the gas train Input is set my the main gas pressure regulator adjustment Main Gas Cocks For manual shutoff of the gas supply upstream of the pressure regulator A second shutoff cock downstream of the main gas valve s provides a means of testing for leakage through the gas valve s High Gas Pressure Switch A pressure actuated switch that remains closed when gas pressure is below a pre selected setting Should the pressure rise above the setting the switch contacts will open causing main gas valve s to close This switch requires manual reset after being tripped Low Gas Pressure Switch A pressure actuated switch that remains closed when gas pressure is above a pre selected setting Should the pressure drop below this setting the switch contacts will open causing main gas valve s to close This switch requires manual reset after being tripped 1 4 IC SA 1714 11 2012 MTH Series Manual Introduction
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