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IC-SA-1249 K Series Manual 3-2011

1. 2 10 IC SA 1249 revised 2011 K Series Manual 2 7 Installation Checklist INDUSTRIAL COMBUSTION 2 Installation Checklist 1 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 a Electrical terminals in the control panel and on all electrical components b Pipe fittings and unions c Tubing connections d Nuts bolts screws Open all necessary oil shutoff valves Do not run pumps or fuel unit without oil Before connecting electrical current to any component be sure the voltage is the same as that specified on component nameplates Before burner operation be sure all motors are rotating in the proper direction Before firing make sure the burner firing head and dry areas of the boiler are protected with refractory The burner mounting flange must be properly sealed against the vessel front plate Make certain that the operator in charge is properly instructed in operation and maintenance procedures AN Caution Before opening the manual gas shutoff valves read the regulator instructions carefully The instructions are in the reg ulator box Follow the manufacturer recommendations Open the shutoff valve on the inlet side of the regulator slowly and carefully to allow inlet pressure to buildup slowly in the regulator until it is fully pressurized Opening the shutoff valv
2. K SERIES Installation Operation and Service Manual INDUSTRIAL COMBUSTION WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SER VICE THIS EQUIPMENT IC SA 1249 03 11 INDUSTRIAL COMBUSTION K SERIES Installation Operation and Service Manual Manual Number IC SA 1249 Release Date March 2011 INDUSTRIAL COMBUSTION Copyright 2011 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 www ind comb com INDUSTRIAL COMBUSTION PREFACE OPERATING PRECAUTIONS This operating manual presents information that will help to properly operate and care for the eguipment Study its contents carefully The unit will provide good service and continued operation if proper operating and maintenance instructions are followed No attempt should be made to operate the unit until the principles of operation and all ot the components are thoroughly understood Only trained and authorized personnel should be allowed to operate adjust or repair this equipment If you are operating a burner s it is your responsibility to ensure that such operation is in full accordance with all applicable safety requirements and
3. position Main flame will come on and the burner is in the low fire position 6 Start and stop the burner several times to ensure proper pilot setting 4 Low High Off amp Low High Low Burner Adjustments Refer to the burner data plate located inside the control panel door The nameplate will list the burner informa tion e burner and control voltage e phase e Cycle e motor amperage e maximum and minimum fuel input settings e manifold pressure at zero furnace pressure add the furnace pressure to get the correct manifold pressure at maximum firing rate These procedures assume that the pre startup tasks check list electrical interference test and pilot turndown tests have been performed in accordance with the instructions in this manual Allow the boiler to fully warm up before making adjustments for most efficient combustion Refer to the boiler instruction manual for the boiler controls settings 4 7 1 Gas Burners The gas burner adjustments on a Low High Off system consist of the gas pressure regulator butterfly gas valve low and high gas pressure switches and air damper The auxiliary switch inside the M436 Mod motor makes or breaks the high fire gas The Low High Low boiler control energizes the M436 motor driving it to high fire When the boiler control de energizes the M436 a built in return spring drives it to the low fire position 4 8 IC SA 1249 revised 2011 K Series Manual 4 7
4. Low High Off 8 Low High Low Burner Adjustments INDUSTRIAL COMBUSTION The Size 1 KG 13 to 25 use a Honeywell V4944 two stage solenoid operated diaphragm valve No butterfly valve is used This valve uses two pressure regulators low fire and high fire and two solenoids to provide two distinct stages of pressure regulation High fire is obtained when the second style solenoid is energized by the auxiliary switch in the M346 Mod motor 1 Open the manual gas shutoff cocks 2 Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator Make sure they are in accordance with the regulator specifications The gas pressure required at the manifold is the pres Sure that is required to fire the burner at its rated capacity To adjust the regulator unscrew the cap located on top and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 3 Turn the burner switch to the ON position 4 Set the thermostat or control to energize the V4944 valve and check the final outlet pressure Allow enough time for the pressure to stabilize valve outlet pressure measurements are made at a point approximately five pipe diameters downstream from the valve outlet Low fire range is 0 85 WC to 2 0 WC for natural gas and high fire outlet range is 3 WC to 4 5 WC 5 o adjust the pressure temporarily remove the slotted aluminum screw cap and gasket from the hou
5. 5 6 Ignition Electrode Cable and Pilot 5 4 5 Flame Scanner 5 4 5 8 Burner Mounting Inspection 5 4 5 9 Extended Shutdown 5 5 5 10 Maintenance Flow Chart Recommended Test Schedule 5 6 CHAPTER 6 Troubleshooting 6 1 6 1 Awareness 6 1 6 2 Emergency Shutdown 6 2 6 3 Troubleshooting 6 3 WARRANTY POLICY STARTUP SERVICE REPORT iv IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION CHAPTER 1 Introduction 1 1 Overview Industrial Combustion K Series burners are assembled wired and tested at the factory They are listed by the Underwriters Laboratory and cUL CSD 1 XL GAP FM and other regulatory agency control options are avail able The operator of this equipment must be familiar with the individual functioning of all controls to understand the operations and procedures described in this manual and supplementary instructions provided with optional con trols N Caution Only factory authorized burner service personnel should start up adjust or service this equipment 1 2 Description The Industrial Combustion K Series burners are designed to operate with gas and light oil The burners are designed for automatic unattended operation except for periodic inspection and maintenance The control panel components require little attention except for occasional cleaning The burners are available in the following configuration Size 1 K13 25 Low High
6. AN Caution All power must be disconnected before servicing valves 5 2 IC SA 1249 revised 2011 K Series Manual 5 4 Oil System INDUSTRIAL COMBUSTION 5 3 2 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 shut off to determine that it opens and closes If the valve has a visual indicator observe its position for correct operation 5 4 Oil System Little maintenance is required on the oil system other than cleaning the oil filter This procedure should be done at regular intervals An increased inlet vacuum reading may indicate a clogged filter Follow the strainer manufac turer s maintenance schedule Maintenance checks on the flexible coupling between the fuel unit and motor for alignment tightness and wear and oil piping connection tightness should also be made at regular intervals Access the coupling by removing the airbox cover and loosening the two setscrews on the flex coupling The oil nozzle should be checked Inside the nozzle lies a small screen that keeps out any particle not caught by the strainer These particles will interfere with the normal oil flow pattern exiting the nozzle A distorted flame can indicate a clogg
7. Oil Pressure Switch Blast Tube Pressure W C Oil Valve w PO C Inter Steam Pressure PSIG lock O NE m NE NE NE mE ME E MA High Gas Pressure Switch _ Low Gas Pressure Switch mE NE HD NE HE Iu Ly Eu MN Gas Valve PO C Interloc Vacuum Oil Pump HG Pilot Turndown Test BEN Flame Signal Pilot For Low NOx Burners Blast Tube Temp Interlock OT IS IN EE NENNEN Lt EE NENNEN poU PIE Jp uH LE OT OT E EE Gas Pressure Bumer Imer Marioa EA ears rete a easier Gas Presse TWO RAS 1 tas Pressure Realtor Out Pse TT Pilot Gas Pressure Regulator Outlet W C Adjusted by Date Accepted by Signature Reguired INDUSTRIAL COMBUSTION IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION Warranty Policy Limited Warranty The Company warrants that at the time of shipment the equipment manufactured by it shall be merchantable free from defects in material and workmanship and shall possess the characteristics repre sented in writing by the Company The Company s warranty is conditioned upon the equipment being properly installed and maintained and operated within the equipment s capacity under normal load conditions with com petent supervised operators Equipment accessories and other parts and components not manufactured by the Company are warranted only to the extent of and by the original manuf
8. Reassemble in reverse order SET ELECTRODE TIP AT THE 9 00 O CLOCK POSITION ELECTRODE END WITHIN 174 FROM TUBE END TIP TO TUBE GAP OF 1 32 Size 3 amp 4 Gas Pilot FIGURE 4 1 Gas Pilot Electrodes 4 4 IC SA 1249 revised 2011 K Series Manual 4 5 Burner Settings INDUSTRIAL COMBUSTION Measure the position and gap of the pilot electrodes and compare them to the dimensions on Figure 4 2 Adjust as follows 1 Loosen the locking screws on the spark ignition clamp assembly 1 8 BETWEEN INNER EDGES OF THE ELECTRODES 7 16 FROM CENTER OF NOZZLE TIPS TO BOTTOM EDGE OF THE eee 1 4 FROM NOZZLE TIPS TO OUTER EDGE OF THE ELECTRODES FIGURE 4 2 Electrode Position and Gap 2 3 Rotate and slide each electrode in the clamp as necessary to achieve the correct position relative to the burner tip Tighten the locking screws securely to lock the electrode in position Apply a lock tight type compound to the screws before tightening Measure the position of the tip of the nozzle to the diffuser and compare to the following drawer assembly draw ings To adjust 1 2 3 Loosen the locking screws on the diffuser clamp Slide the diffuser clamp along the length of the burner pipe until the correct dimension is achieved Tighten the diffuser clamp securely to the burner pipe Apply a lock tight type compound to the screws before tightening Carefu
9. and scribe vertical centerline Be sure stud locations line up where studs will have full support If they don t or if the opening is too large a steel adapter plate 3 8 minimum may be welded or bolted in place suitable anchors should be provided to hold the refractory in place The adapter plate must be properly sealed use insulating rope gasket to prevent leakage of combustion gases 3 Using the insulating rope gasket wrap the rope on the inside of the bolt circle looping the rope around the four mounting studs 4 Set the burner into position for mounting and tighten into place Sizes 1 2 and 3 burners are provided with four lugs to secure the burner to the front plate Size 4 burners are equipped with a four hole mounting flange 5 Permanently support the burner using the pipe support connections e he space between the boiler refractory water leg or firetube and outside diameter of the blast tube must be packed with plastic refractory Kaiser Refractory Mono T Air Set or equal Ram plastic refractory from front to rear parallel to the outside surface of the blast tube 2 2 IC SA 1249 revised 2011 K Series Manual 2 4 Burner Installation USTRIAL COMBUSTION Support Burner Here FIGURE 2 1 Burner Mounting Support BLANKET INSULAT ING T rj 2 DE O vi C Lu a ml a i ud SES Lil E Lil 5 L uz uu ME il ud HF Lil 3 O Lu 3 i km mE D Li
10. are shipped loose to be mounted by the installer NOTE The pilot gas supply connection must be upstream of the main gas pressure regulator GAS PILOT LINE BLOWER MOTOR GAS BUTTERFLY VALVE COMBUSTION AIR SWITCH IGNITION TRANSFORMER OIL PUMP MODULATING MOTOR CONTROL PANEL FIGURE 1 1 Burner Unit IC SA 1249 revised 2011 1 5 K Series Manual Introduction INDUSTRIAL COMBUSTION _ GAS MANIFOLD MOUNTING FLANGE NOZZLE BODY amp TIP AIR BAFFLE GAS ORIFICES FIGURE 1 2 Burner Internal Components 1 6 IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION CHAPTER 2 Installation 2 1 Draft Conditions A boiler or other heating vessel fired with an K Series burner does not depend on chimney draft for proper com bustion air Combustion air is supplied by the burner forced draft blower providing adequate air for any normal combustion condition Since draft control is essential to maximum efficiency a draft regulator may be required when the vessel is con nected to a tall stack or where wind conditions may cause erratic draft Excessive furnace draft contributes to inefficient burner operation Sealed boilers may be operated under positive firebox pressure within the capability of the burner 2 2 Combustion Air Supply The space in which a burner operates must be supplied with adequate fresh air for combustion and ventilation purposes Fresh air
11. assistance in pinpointing problems that may not be readily apparent The program relay has the capability to self diagnose and to display a code or message that indicates the failure condition Refer to the control bulletin for specifics and suggested remedies IC SA 1249 revised 2011 6 1 K Series Manual Troubleshooting INDUSTRIAL COMBUSTION Familiarity with the programmer and other controls in the system may be obtained by studying the contents of this manual Knowledge of the system and its controls will make troubleshooting that much easier Costly down time or delays can be prevented by systematic checks of actual operation against the normal sequence to deter mine the stage at which performance deviates from normal By following a set routine may possibly eliminate overlooking an obvious condition often one that is relatively simple to correct If an obvious condition is not apparent check each continuity of each circuit with a voltmeter or test lamp Each circuit can be checked and the fault isolated and corrected In most cases circuit checking can be accomplished between appropriate terminals on the terminal boards in the control cabinet or entrance box Refer to the wiring schematic supplied for terminal identification Caution Never attempt to circumvent any of the safety features The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to restart Failu
12. assure low resistance connections The relay chassis is mounted on the subbase 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 fuses in the main panel and in the burner control cabinet Check wiring to the burner control cabinet for compliance with the wiring diagram and local codes The control cabinet components are 120 volt If a control transformer is supplied ensure that the supply voltage matches its primary voltage Check motor rotation by momentarily closing the starter or relay Blower rotation is clockwise when viewed from the drive end Check the pilot electrode setting Refer to Chapter 4 Check control linkage for proper movement of the air volume damper and fuel metering com ponents This can be done by loosening the linkage at the actuator lever and manipulating by hand Check the air shutter and adjust the low fire setting Refer to Chapter 4 IC SA 1249 revised 2011 K Series Manual 3 1 Starting Up and Operation INDUSTRIAL COMBUSTION 3 2 Firing Preparations Check to make certain that all plugs connections linkages etc are tight Prior to initial firing oil flow and pres sure should be verified 3 2 1 Gas Burners A representative of the gas utility should turn on the gas Determine by a test gauge upstream of the burner reg ulator that sufficient
13. coupled to the modulating motor plus two adjustable but non modulating air shutters NOTE The Low High Off Low High Low burners are equipped with a single air damper blade The special air shut ter design is applicable only for the full modulation systems The modulating main air shutter regulates the flow of inlet air through the fan at flow rates between high fire and low fire conditions according to the modulating motor position One non modulating air shutter for high fire com bustion air control is adjusted to provide the correct amount of air while the system is operating at high fire fuel input rate with the main air shutter fully open The other non modulating shutter for low fire combustion air con trol is adjusted to provide the correct amount of air with the system operating at low fire input rate with the main shutter completely closed The three air shutters are mounted inside the air box assembly The high fire and low fire shutters are mounted on independent shafts A pointer mounted on each shaft indicates the set position of each non modulating shutter Adjustment of these shutters is accomplished by loosening a setscrew that holds the shutter shaft within a stationary collar mounted on the air box 4 2 IC SA 1249 revised 2011 K Series Manual 4 3 Gas Pilot Flame Adjustment INDUSTRIAL COMBUSTION 4 2 5 Combustion Settings Fuel and air flow rates are individually adjusted at low fire
14. flame detector proves the presence of a satisfactory pilot the programmer will proceed to main flame ignition 4 Make initial air shutter settings for smooth ignition Return line oil pressure should be set according to the information in Chapter 4 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 5 Set the oil low fire rate by adjusting the oil return pressure and air linkage Refer to Chapter 4 6 Using the combustion analysis instrument adjust the low fire Typical combustion analysis for low fire is 4 0 to 6 5 O 7 When low fire is adjusted shut down the burner Restart several times to be sure the low fire setting Is suit able Readjust if necessary Never start the burner with fuel vapor in the furnace In case of emergency open the main power switches and close all fuel valves After combustion adjustments are satisfactorily set allow the heating vessel to slowly reach normal operating pressure or temperature s After the boiler has reached operating temperature or pressure turn the potentiometer switch in small incre ments to the high fire position This will cause the metering valve to close resulting in an increase in the oil pressure feeding the burner nozzle In high fire the oil metering valve should be in the fully closed position and the fuel oil pressure should be about 300 psi Check hig
15. heat transfer or by reducing excess combustion air A certain amount of excess air is necessary to complete combustion More efficient burn ers require minimum excess air IC SA 1249 revised 2011 4 1 K Series Manual Adjustments INDUSTRIAL COMBUSTION 4 2 2 Smoke Measurement smoke measurements can be made using a variety of different methods The standards will vary somewhat according to the eguipment used and instructions accompanying the instrument should be followed Smoky combustion can result from e improper air delivery e insufficient draft e improper fuel viscosity e improper air fuel ratio e excessive air leaks in the combustion chamber e improper fuel oil temperature 4 2 3 Test Equipment The following test equipment should be used to setup and adjust the burner correctly 1 Combustion analyzer with 05 or CO indication 2 U Tube manometer or pressure gauge to measure gas pressures main and pilot vacuum and pressure gauges for oil Inclined manometer to measure draft pressures omoke spot tester for oil burners and CO analyzer for gas fired units Voltmeter Ammeter otack thermometer and thermocouples 2 m e p 4 2 4 Air Flow Adjustments The K Series burners have a unique air shutter design that enables precise independent air flow rate adjust ments for both the high fire and low fire operating points This design incorporates a variable main air shutter mounted on a shaft and direct
16. pressure exists at the entrance to the gas train The gas pressure regulator must be adjusted to the pressure required and the pressure setting recorded On combination fuel models set the selector switch to gas 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 deter mine that the main gas valve opens Turn the burner switch OFF and let the programmer complete its cycle Check to see that the gas valve closes tightly On burners equipped with high and low gas pressure switches set the switch pressure actuating levels and record the settings for future service reference see the burner specification nameplate inside the control panel door for minimum and maximum input rate and required manifold pressure When the conditions covered above and in Chapter 2 are assured the burner is ready for firing Refer to Section 3 5 for starting and operating information 3 2 2 Oil Burners Prior to initial firing oil flow and pressure should be veritied If the burner is a dual fuel model make certain that the main gas shutoff cock is closed and the fuel selector switch is set to OIL 3 2 3 Oil Flow If the oil supply tank is below the level of the oil fuel unit it is recommended that the suction line be primed with oil prior to starting the pump to avoid the possibility of damage to the pump through operation without lubrica
17. proper read ings adjust the gas butterfly opening and low fire air shutter Take note of the readings and pressures at the burner manifold and gas train Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water Then increase the fuel input to the boiler by turning the manual flame control potentiometer towards OPEN in small increments This will cause the butterfly valve to open allowing more gas into the burner At each point allow the burner to operate for a few minutes before recording the O5 CO and pressure read ings Observe that the 05 and CO levels remain within an acceptable limit Adjust the pressure regulator as necessary to correct this situation For burners with the cam trim option adjust the cam screws throughout the range to obtain correct O and CO levels Continue to do this until the burner reaches high fire the poten tiometer is at the OPEN position Adjust the high fire gas input to match maximum rating At high fire the butterfly valve should be near the full open position Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate Verify and record the readings and pressures High fire is typically 2 to 4 Os with less than 50 ppm CO as a target value Adjust the high fire excess air rate using the high fire shutter adjustment Modulate the burner to low fire Again verify the readings The burner should be adjusted to provide
18. supply must meet or exceed all code requirements Consult with the insurance carrier and or local authorities for specific regulations The boiler room pressure must be at least equal 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 2 3 Combustion Chamber Design Suggested Minimum Combustion Chamber Dimensions shown on the following table are based on the rated capacity of the burner While these dimensions are typical for good practice satisfactory results may be achieved with modifications to suit some conditions Factors such as fuel properties total combustion volume and length of flame travel often make fixed requirements impractical When in doubt consult the factory Insulation should be provided between the burner mounting flange and the boiler adaptor plate IC SA 1249 revised 2011 2 1 K Series Manual Installation INDUSTRIAL COMBUSTION AN Caution The gasket must be resilient to seal any uneven areas between the burner flange and the boiler front plate to prevent leakage of combustion gases 13 5 Ca 3 135 gt D 2 4 Burner Installation Prepare the boiler front plate as follows 1 Determine the burner mounting height Locate and scribe a level horizontal centerline across the mounting face 2 Locate
19. to ON The burner will start and pre purge After pre purge the ignition trans former and the gas pilot solenoid are energized 5 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 Determine that the main gas valve opens When this is con firmed turn the burner switch to OFF and allow the programmer to finish its cycle 6 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 7 Turn the burner ON and after pilot ignition when the flame relay pulls in the slow opening motorized main gas valve is energized Slowly open the downstream manual shutoff gas cock Main flame should ignite at this time The gas Valve and air damper continue advancing until high fire is reached 3 5 1 3 Setting Combustion Do not repeat unsuccessful light off attempts without rechecking the burner and pilot adjustment Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt Set the gas low fire rate by adjusting the butterfly valve and air linkage Referring to the Chapter 4 and using a combustion analyzer adjust the low fire ratio typical combustion analysis for low fire is 4 to 5 O on standard turndown systems Verify the minimum input rate by measuring the gas meter When low fire is ad
20. 1 he fuel valve s de energize and the flame extinguishes The blower motor continues running during post purge If so equipped with the post purge feature 2 At the end of the post purge the blower motor is de energized The programmer returns to its starting position and stops The unit is ready to restart Abnormal shutdown might result from motor overload flame outage low water current or fuel supply interrup tion combustion or atomizing air pressure below minimum level tripped circuit breakers blown fuses or other interlock devices Check for the cause and correct it before restarting the burner Safety shutdown caused by ignition or flame failure will actuate 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 dur ing 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 IC SA 1249 revised 201 1 3 9 K Series Manual INDUSTRIAL COMBUSTION Starting Up and Operation 3 10 IC SA 1249 revised 2011 K Series Manual 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 reguire fu
21. 145 are supplied with a gas pilot system Gas and combination gas oil models are supplied with a gas ignition system The standard pilot gas train consists of a manual shutoff cock a gas pressure regulator and a solenoid operated gas shutoff valve 1 8 Gas Handling System Depending upon the requirements of the regulating authority the gas control system and gas train may consist of some or all of the following items 1 Gas Volume Valve The butterfly type valve is positioned by linkage from the modulating motor and controls the rate of flow of gas 2 Main Gas Valves Electrically operated safety shutoff valve s that open to admit gas to the burner Standard U L burners include Models 13 25 one gas diaphragm valve and one safety solenoid valve Models 30 42 one motorized gas valve w proof of closure Models 54 145 one motorized gas valve w proof of closure and one safety solenoid valve 3 Main Gas Regulator Regulates gas train pressure to specified pressure required at the burner manifold Input is set by main gas pressure regulator adjustment 4 Main Gas Cocks Used for manual shutoff of the gas supply upstream of the pressure regula tor A second shutoff cock downstream of the main gas valve s provides a means of testing for leakage through the gas valve s 5 High Gas Pressure Switch A pressure actuated switch that remains closed when gas pressure is below Models 25 145 a selected setting Should the pressure rise abo
22. L COMBUSTION gas involves balancing the input rate only against the existing flow of combustion air as established initially for oll NOTE Do not readjust the air shutter when turning the combination burner for combustion of natural gas 1 Turn the fuel selector switch to the OIL position 2 Turn the burner switch to the ON position 3 Proceed with startup and adjustments using the same procedures explained in Section 4 7 2 Oil Burners 4 After the system has been completely adjusted for oil firing turn the burner switch OFF and position the fuel selector switch to GAS 5 Proceed with startup and adjustments using the same procedures explained in Section 4 7 1 Gas Burners Do not alter the air settings set for oil 6 Correct O levels by adjusting the butterfly valve for Size 2 models and the regulators low and high pressures for Size 1 models 4 8 Full Modulation Burner Adjustments Refer to the burner data plate located inside the control panel door The nameplate will list the burner informa tion e burner and control voltage e phase e cycle e motor amperage e maximum and minimum fuel input settings e manifold pressure at zero furnace pressure add the furnace pressure to get the correct manifold pressure at maximum firing rate These procedures assume that the pre startup tasks checklist electrical interference test and pilot turndown tests have been performed
23. Off HEN PP size 2 K30 42 Low High Off HEN PP Size 3 K54 84 Full Modulation Size 4 K105 145 Full Modulation IC SA 1249 revised 2011 1 1 K Series Manual Introduction INDUSTRIAL COMBUSTION 1 3 Operating Controls Panel The control panel contains a flame safeguard programming control motor relays starters and terminal strips mounted internally on a panel subbase Lights switches and a control circuit breaker are mounted externally on the panel as indicated below 1 On Off Burner Switch On Off selector switch 2 Fuel Selector Switch e Gas Position Selects gas as the firing fuel e Off Position Burner off e Oil Position Selects oil as the firing fuel 3 Control Circuit Breaker supplementary low overcurrent protection only No larger than 15 amps 4 Auto Manual Modulation Selector e Auto Position Selects boiler modulation control In this position the Switch burner will operate automatically in response to load demand e Manual Position Selects 135 ohm potentiometer for manual modulating control 5 Manual Modulating Control 135 ohm for full modulation burners only increases or decreases the burner firing rate manually 6 Signal Lamps Power On white Illuminates when the control circuit is energized pow ered Ignition amber Illuminates when the ignition transformer is powered and pilot valve is energized opened Main Fuel green llluminates when the main fuel valve or valves a
24. Performing a Gas Valve Leak Test Bubble Test 3 4 3 5 1 2 Initial Startup 3 6 3 5 1 3 Setting Combustion 3 6 3 5 2 Oil Burners 3 6 3 6 Combination Gas Oil Burners 3 7 3 Normal Operation 3 8 3 8 Shutdown 3 9 ii IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION CHAPTER 4 Adjustments 4 1 4 1 Overview 4 1 4 2 Combustion Adjustment on Oil and Gas 4 1 4 2 1 Stack Temperature 4 1 4 2 2 Smoke Measurement 4 2 4 2 3 Test Equipment 4 2 4 2 4 Air Flow Adjustments 4 2 4 2 5 Combustion Settings 4 3 4 2 6 Gas Adjustments 4 3 4 2 7 Fuel Oil Adjustments 4 3 4 3 Gas Pilot Flame Adjustment 4 3 4 4 Direct Spark Oil Pilot Adjustment 4 4 4 5 Burner Settings 4 4 4 6 Pilot Turndown Test 4 8 4 7 Low High Off amp Low High Low Burner Adjustments 4 8 4 7 1 Gas Burners 4 8 4 7 2 Oil Burners 4 10 4 7 3 Combination Gas Oil Burners 4 10 4 8 Full Modulation Burner Adjustments 4 11 4 6 1 Gas Burners 4 11 4 8 2 Oil Burners 4 12 4 6 3 Combination Gas Oil Burners 4 13 CHAPTER 5 Maintenance 5 1 5 1 Overview 5 1 5 2 Control System 5 1 5 2 1 Programming Control 5 2 5 2 2 Motors 5 2 9 3 Gas System 5 2 5 3 1 Solenoid Valves 5 2 5 3 2 Motorized Main Gas Valves 5 3 IC SA 1249 revised 2011 iii K Series Manual INDUSTRIAL COMBUSTION 5 4 Oil System 5 3 5 5 Drawer Assembly 5 3
25. RETURN TO TANK y CHECK VALVE SUPPLY TO BURNERS CHECK VALVE FIGURE 2 9 Multiple Burners with Separate Suction Lines RETURN TO TANK Hp WASOLATOR PRESSURE GAUGE ba i PRESSURE GALNGES WASOLATORS Em is VALVE VOLUME T iS 316 312 t mus ae CONTROL n EBS a A i H BY PASS CATE Mega A i WALVE i CIL RETURN AR i ball 3 P METERING FUEL VALVE FILTER UNIT VACUUM OR COMPOUND GAUGE W ISOLATOR GATE GATE a VALVE VALVE CHECK l gt x VALVE a T e TI EL I Hj T Hs 0 E MERI STRAINER FIGURE 2 10 Typical Oil Loop for Multiple Burners with Transfer Pump awl j E dx li T T il a bas i a t lt i TEES 1 IL a i OIL RETURN e rt i OIL INLET ds OIL METERING FUEL VALVE UNIT P BACK PRESSURE VALVE A SETBELOW3 PSI ry METERING FUEL VALVE FILTER UNIT RELIEF VALVE ls k tel TER TRANSFER kaud PUMP ab i IC SA 1249 revised 201 1 K Series Manual 2 9 Installation INDUSTRIAL COMBUSTION ja i l l l VACUUM OR COMPOUND GAUGE W ISOLATOR 2 TRANSFER L PUMP STRAINER FIGURE 2 11 Typical Installation Using Day Tank VACUUM BREAKER q 6 MINIMUM CHECK VALVE PRESSURE GAUGE x Fe ig LE SUPPLY STRAP VACUUM GAUGE TANK d TRANSFER PUMP DUPLEX PUMP SYSTEM FIGURE 2 12 Typical Flooded Loop System
26. Special pressure regulating valves are available for suction pressure above 3 psi The fuel unit discharge pressure should be set at 300 psi 3 2 5 Burner Settings To ensure reliable and safe burner performance the location and gap setting of the electrode for direct spark igniters and the relative positions of the burner nozzle diffuser and air baffle components must be correctly set The air damper blades must be adjusted relative to the established flow rates to provide the correct amount of air for complete efficient combustion These items are preset at the factory but must be checked prior to placing the burner into initial service or after conducting any service work that may have altered their positions Refer to Chapter 4 3 2 6 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 nameplate inside the control panel for minimum and maximum fuel input ratings Also refer to Chapter 4 3 2 7 Test Equipment The following test equipment should be on site 1 Combustion analyzer with 05 or CO indication 2 U Tube manometer or pressure gauge to measure gas pressures main and pilot pressure and vacuum gauge for the oil burners Inclined
27. TO BACK OF DIFFUSER LOCATE DIFFUSER FACE FLUSH WITH EDGE OF RADIAL GAS HOLES BLAST TUBE p WELDMENT a REF 4 FIGURE 4 5 Size 3 KL 8 KLG 54 to 84 3 3 16 REF DIMENSION FROM NOZZLE TIP TO BACK OF DIFFUSER LOCATE DIFFUSER FACE FLUSH WITH EDGE OF RADIAL GAS HOLES im BLAST TUBE fo WELDMENT a REF FIGURE 4 6 Size 4 KL amp KLG 105 to 145 IC SA 1249 revised 2011 4 7 K Series Manual Adjustments INDUSTRIAL COMBUSTION 4 6 Pilot Turndown Test For burners equipped with a gas pilot conduct the following test 1 Turn the burner switch ON This will start the blower motor and initiate the pre purge sequence Make sure a pressure gauge O to 10 W C or manometer is installed in the pilot line to monitor the pilot gas pressure 2 When the pilot comes on put the programmer timer on pilot hold by placing the RUN TEST switch of the flame safeguard to the TEST position NOTE Refer to the flame safeguard control manual instructions 3 Check the flame signal strength Adjust the flame signal by increasing or decreasing pilot gas pressure with the regulator spring A normal setting is 3 to 4 W C 4 Perform a pilot turndown test by reducing the pilot pressure very slowly until the scanner loses sight of the flame and produces a flame lockout Note the minimum pressure level 5 After adjusting the pressure back to a normal level set the programmer to the RUN
28. Troubleshooting NDUSTRIAL COMBUSTION Problem Possible Causes Pilot Flame but No Main 1 Insufficient pilot flame Flame 2 Gas fired unit a Manual gas cock closed b Main gas valve inoperative c Gas pressure regulator inoperative 3 Oil fired unit a Oil supply cut off by obstruction closed valve or loss of suction b Supply pump inoperative c No fuel Broken loose or missing oil pump coupling d Main oil valve inoperative e Check oil nozzle gun and lines 5 Binding or loose linkages cams setscrews etc IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION Problem Possible Causes Shutdown Occurs During 1 Loss or stoppage of fuel supply Firing 2 Defective fuel valve loose electrical connection 3 Flame detector weak or defective 4 Scanner lens dirty or sight tube obstructed 5 If the programmer lockout switch has not tripped check the limit circuit for an opened Safety control 6 If the programmer lockout switch has tripped a Check fuel lines and valves b Check flame detector c Check for open circuit in running interlock circuit d The flame failure light is energized by ignition failure main flame failure inadequate flame signal or open control in the running interlock circuit 7 Improper air fuel ratio lean fire a Slipping linkage b Damper stuck open c Fluctuating fuel supply Temporary obstruction in the fuel line Temporary dr
29. acturer s warranty to the Company In no event shall such other manu facturer s warranty create any more extensive warranty obligations of the Company to the Buyer than the Com pany s warranty covering equipment manufactured by the Company Exclusions From Warranty 1 THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES ORAL OR EXPRESS OR IMPLIED INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION OF THE EQUIP MENT 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 PUR POSE THE PROVISIONS AS TO DURATION WARRANTY ADJUSTMENT AND LIMITATION OF LIABILITY SHALL BE THE SAME FOR BOTH IMPLIED WARRANTIES IF ANY AND EXPRESSED WARRANTIES 11 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 Company s home office within thirty 30 days of the discovery of any defect The Company agrees at its option to repair
30. and at high fire to achieve rated input firing rate turn down optimum efficiency safe operation and the ability to cope with environmental changes including air tem perature humidity barometric pressure and fuel property changes Turndown capability for oil is less than that for gas due to the excess air requirement of oil for clean combustion Therefore on combination fueled burners gas turndown performance may be restricted or determined by the excess air levels set initially for oil combustion Two key components residing in flue gas are used to optimize combustion efficiency excess air and unburned fuel The system should be adjusted to the minimum excess air quantity that provides low levels of unburned fuel with sufficient remaining oxygen to cope with normal atmospheric and fuel related changes Unburned fuel is measured as carbon monoxide CO when burning natural gas and smoke spots when burning oil 4 2 6 Gas Adjustments Low fire combustion analysis is typically 7 to 9 CO and less than 04 CO 400 ppm A high fire reading is typically 9 to 10 5 O and less than 04 CO The K Series burners are capable of operating at low excess air and less than 50 ppm CO levels at all firing rates 4 2 7 Fuel Oil Adjustments Adjust for a clean fire typically for No 2 oil CO is 8 to 11 at low fire and 10 to 13 at high fire The burner should be set up and maintained to yield smoke spot levels less than a 1
31. arning and caution references have been made in this manual and should be adhered to for smooth operation of the burner This symbol precedes information which if disregarded may result in injury to the user of the burner or others N Caution This symbol precedes information which if disregarded may result in damage 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 Mode Ful Momgaon G Example The model number on the nameplate is KLG 42 indicating it is a combination No 2 oil and gas burner with input rated at 4 200 MBTU per hour against furnace pressure up to 1 5 W C The installation of a burner shall be in accordance with the regulations of authorities having jurisdic tion The equipment must be installed in accordance with applicable local state or provincial instal lation requirements including the National Electrical Code NEC and Associated Insurance Underwriters INDUSTRIAL COMBUSTION 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 K Series burners are designed to burn either gas or light oil No 1 or No 2 as defined by ASTM D396 2010 S
32. circuit not completed no voltage at end of limit circuit program relay terminal Pressure or temperature is above setting of operation control Water below reguired level Low water light and alarm horn should indi cate this condition Check manual reset button if provided on low water control Fuel pressure must be within settings of low pressure and high pressure switches Check burner air proving switch and high fire limit switch 4 High or low gas pressure investigate and repair No Ignition 1 Lack of spark a Electrode grounded or porcelain cracked b Improper electrode setting c Loose terminal on ignition cable cable shorted d Inoperative ignition transformer e Insufficient or no voltage at pilot ignition circuit terminal 2 Spark but no flame a Lack of fuel no gas pressure closed valve empty tank broken line etc b Too much air flow c No voltage to pilot solenoid d Defective pilot solenoid e Improperly positioned electrode direct spark models 3 Low fire switch open in low fire proving circuit a Damper motor not closed slipped cam defective switch b Damper jammed or linkage binding 4 Running interlock circuit not completed a Combustion proving switches defective or not properly set b Motor starter interlock contact not closed 5 Flame detector defective sight tube obstructed or lens dirty IC SA 1249 revised 2011 6 3 K Series Manual
33. codes Placed on all Industrial Combustion burners are warning or caution lables designed to inform the operator of potential hazards and stress important information These symbols and their meanings are as follows Failure to install and operate this equipment in accordance with the manufacturer s recommended instructions and industry standards and practices can result in fire explosion property damage and or personal injury Read this manual in its entirety prior to any attempt to commission this equipment Installation startup operation and maintenance of this equipment must be performed only by factory authorized experienced and qualified personnel Hazard of electric shock More than one disconnect may be required to disconnect all power to this panel serious personal injury or death may result To avoid personal injury from moving parts shut off all electrical power before servicing this equipment Read product manual and fully understand its contents before attempting to operate this equipment IF these instructions are not followed serious personal injury or death may result INDUSTRIAL COMBUSTION N Caution Provide support for this panel to prevent damage to electrical components N Caution Only factory authorized berner service personnel should startup adjust or service this equipment N Caution After final fuel input adjustments are made verify fuel input by meter if possible Further w
34. correct fuel flow at a constant rate at the low fire and high fire posi tions as indicated on the burner data plate This is achieved by clocking the gas flow at the gas meter The gas utility or gas meter calibration data should be consulted to determine the correction factors to be applied to the meter Use the following formula to determine actual flow 3 Gas Input HHV x Eatm Pegas x 520 x 36002 x Rare ft Btu 29 92 Tgas 460 hr s hr HHV The higher heating value of the gas in Btu ft contact the local gas company for an exact measure ment Patm Atmospheric pressure in inches of mercury Pgas Gas pressure ahead of the volumetric flow meter in inches of mercury Tgas Gas temperature at the volumetric flow meter in degrees F RATE Natural gas rate taken with the volumetric flow meter in ft second Adjust the low and high gas pressure switches by turning the adjusting screw until the indicator moves to a pressure slightly lower than normal operating pressure for the low gas pressure switch and slightly higher for the high gas pressure switch usually 20 below and 20 higher than normal pressure 12 Tighten all linkages and marked settings Complete the Startup report 13 Turn the MANUAL AUTO switch to AUTO The burner will now modulate according to the load demand to the boiler 4 8 2 Oil Burners The oil burner adjustments consist of the oil metering valve and air sh
35. e Ss VALVE Do ae A 5 N MAIN MOD GAS lt 4 X VALVE gt gt Mera 7 BURNER S AD T mo Cy ee REGULATOR O 9 NU 5 input PILOT lt gt T FROM SUPPLY VALVE IGE x UC PILOT SHUTOFF COCK 7 FIGURE 2 3 Typical UL Gas Train Low High Off System K13 to K21 OUTPUT TO BURNER meai A Cz un gt e UGE SHUTOFF COCK A REGULATOR S gt LD QU Sen yy SHUTOFF 3 cock Ls m G ORE BURNER gt O h U 4e z PILOT 4 Ss _ REGULATOR KG i gt PRONM SUPPLY PILOT TE T VALVE E PILOT SHUTOFF COCK FIGURE 2 4 Typical UL Gas Train Full Modulation System K13 to K21 2 6 IC SA 1249 revised 2011 K Series Manual 2 6 Fuel Oil Piping INDUSTRIAL COMBUSTION Tosun VAVE LL PRESSURE P SWITCH d QZ by m LOW GAS PRESSURE A SWITCH S SIS e MAIN VN Dn REGULATOR GAS LC y f KD ha gt FAN HOUSING BACK CAP HE cil a de ll y RN Y Ao N FUEL UNIT FIGURE 2 6 Low High Off Low High Low Oil System Size 2 K30 to K42 2 7 Installation INDUSTRIAL COMBUSTION NOZZLE PRESSURE TAP M C OIL VALVES FAN HOUSING BACK CAP FUEL UNIT PRESSURE OIL TAP NOZZLE FIGURE 2 8 Full Modulation Oil System Sizes 2 3 4 K30 to K145 Return Flow Nozzle 2 8 IC SA 1249 revised 2011 K Series Manual 2 6 Fuel Oil Piping NDUSTRIAL O OMBUSTION
36. e metering valve to close resulting in an increase in the oil pressure feed ing the burner nozzle 6 At each point allow the burner to operate for a few minutes before recording the CO Cl Smoke and pres sure readings Observe that the CO and Cl levels remain within an acceptable limit Adjust the oil pressure as necessary to correct his situation For burners with the cam trim option adjust the cam screws throughout the range to obtain correct CO and CO levels Continue to do this until the burner reaches high fire the potentiometer is at the OPEN position 7 Adjust the high fire fuel input to match maximum oil pressure At high fire the metering valve should be in the fully closed position and the pressure should be 300 psi Verify and record the readings and pressures High fire is typically 11 to 13 Co with less than No 2 Smoke Adjust the high fire excess air rate using the high fire shutter adjustment 8 Modulate the burner to low fire Verify the readings once again The burner should be adjusted to provide cor rect fuel flow at a constant rate at the low fire and high fire position as indicated on the burner data plate 9 Tighten all linkages and marked settings Complete the Startup Report 10 Turn the MANUAL AUTO switch to AUTO The burner will now modulate according to the load demand to the boiler gt e Y N 4 8 3 Combination Gas Oil Burners In general the combination fueled system is
37. e quickly will damage the regulator Do not exceed the regulator pressure ratings IC SA 1249 revised 2011 2 11 K Series Manual INDUSTRIAL COMBUSTION Installation 2 12 IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION CHAPTER 3 starting Up and Operation 3 1 Preparation for Initial Startup When the installation is complete and all electrical fuel water and vent stack connections are made make cer tain these connections are tight The operator should become familiar with the burner boiler controls and com ponents Adjustment procedures given in Chapter 4 should be reviewed prior to firing The wiring diagram should also be studied along with the operating sequence of the burner programmer Check the electrical power supply for accordance with the nameplate specifications for all motors and controls Read and understand starting instructions before attempting to operate the burner The following checks must be made Component spect Boiler Burner Check boiler water level Be sure all boiler valves are installed correctly and positioned prop erly Set the high limit control slightly above the operating control Set the operating control at the desired temperature or pressure 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
38. e with the oil pressure regulating valve to have approximately 100 to 200 psi and adjust the air shutter for a clean fire Record the combustion reading from the flue gas analyzer normally 8 to 11 O and less than No 2 Smoke Bacharach To adjust the oil pressure regulating valve remove the lockscrew and adjust pressure by turning the Allen screw clockwise to increase pressure and counterclockwise to decrease pressure 3 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water 4 Adjust the high fire fuel input to match maximum oil pressure At high fire the pressure should be 300 psi Verify and record the readings and pressures High fire is typically 11 to 13 CO with less than No 2 smoke The burner should be adjusted to provide correct fuel flow at a constant rate at the low fire and high fire position as indicated on the burner data plate 5 Tighten all linkages and marked settings Complete the Startup report 4 7 3 Combination Gas Oil Burners In general the combination fueled system is to be started first using oil because as a fuel oil has a greater com bustion air requirement than natural gas After being completely adjusted for oil combustion the burner is restarted and adjusted using natural gas as fuel Combustion adjustment of the combination burner for natural 4 10 IC SA 1249 revised 2011 K Series Manual 4 8 Full Modulation Burner Adjustments INDUSTRIA
39. eck for loosening of components erosion or carbon buildup Replace or clean the oil strainer elements Inspect and clean the combustion impeller Perform and complete a combustion test Adjust burner if nec essary Read and log data Required after any adjustment to flame scanner or pilot adjustment Refer to instructions IC SA 1249 revised 2011 K Series Manual 5 l e INDUSTRIAL COMBUSTION CHAPTER 6 Iroubleshooting Troubleshooting should be performed only by personnel who are familiar with the equipment and who have read and understood the contents of this manual Failure to follow these instructions could result in serious personal injury or death Disconnect and lockout the main power supply in order to avoid the hazard of electrical shock Failure to follow these instructions could result in serious personal injury or death 6 1 Awareness Chapter 6 assumes that e The unit in question has been properly installed and that it has been running for some time e The operator has become thoroughly familiar with both the burner and the manual by this time The points set forth under each heading are brief possible causes suggestions or clues to simplify locating the source of the trouble Methods of correcting the trouble once it has been identified may be found elsewhere in this manual If the burner will not start or operate properly the Troubleshooting section should be referred to for
40. ed nozzle Inspect and clean the nozzle and screen To clean the screen swirler and tip unscrew the tip from the nozzle body Clean nozzle parts in solvent Never use wire or sharp metal tools to clean the nozzle orifice A metal tool will distort the orifice and ruin the nozzle Reassemble the nozzle The tailpiece must be screwed in with the swirler seating tight against the tip to ensure proper atomization Reassemble the nozzle into the nozzle body If a nozzle is replaced it must be replaced with an identical nozzle make size and Spray angle 5 5 Drawer Assembly The drawer assembly may be removed for inspection and service 1 Shut off the burner turn the ON OFF switch to the OFF position 2 Shut off all electric power to the burner 3 Disconnect the fuel lines from the drawer assembly access cover 4 After making note of where the bolts are located in relationship to the access cover slots remove the drawer assembly access cover bolts Pull the drawer partially out of the housing 5 Reach inside and disconnect the ignition cables from the electrodes for direct spark applications 6 Pull the drawer assembly completely out of the housing To re install 1 Insert the assembly part way into the housing 2 Reconnect the ignition cables if applicable and seat the assembly fully 3 Install the access cover bolts loosely 4 Slide the cover to the original location and tighten the bolts 5 Reconnect the f
41. er Positions and Metering Valve Dial INCREASE GAS VOLUME CONTROL VALVE INCREASE RATE ad DECREASE RATE HOUSING ASSEMBLY CLOCKWISE ROTATION FIGURE 4 8 Linkage Adjustments 4 14 IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION CHAPTER 5 Maintenance 5 1 Overview A maintenance program avoids unnecessary downtime costly repairs and promotes safety It is recommended that a record be maintained of daily weekly monthly and yearly maintenance activities See Section 5 10 Electrical and mechanical devices require systematic and periodic inspection and maintenance Any automatic features do not relieve the operator from responsibility but rather free him from certain repetitive chores provid ing time for upkeep and maintenance Unusual noise improper gauge reading leak sign of overheating etc can indicate a developing malfunction requiring corrective action Only factory authorized burner service personnel should start up adjust or service this equipment AN Caution 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 allowed to be removed They must be replaced and securely anchored before testing adjusting or running the burner or burner related equipment 5 2 Control System Most
42. f Contents CHAPTER 1 CHAPTER 2 Introduction 1 1 1 1 Overview 1 1 1 2 Description 1 1 1 3 Operating Controls Panel 1 2 1 4 Flame Safeguard Controls 1 2 1 5 Combustion Air Handling System 1 3 1 5 1 Operation 1 3 1 6 Oil System 1 3 1 6 1 Operation 1 4 1 7 Pilot System 1 4 1 8 Gas Handling System 1 4 1 8 1 Operation 1 5 Installation 2 1 2 1 Draft Conditions 2 1 2 2 Combustion Air Supply 2 1 2 3 Combustion Chamber Design 2 1 2 4 Burner Installation 2 2 2 5 Gas Piping 2 4 IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION CHAPTER 3 2 6 Fuel Oil Piping 2 4 2 6 1 Pressure Atomization Oil Piping 2 4 2 6 2 Iwo Pipe Single Burner Operation 2 4 2 6 3 Suction Line Sizing 2 5 2 6 4 Return Line Sizing 2 5 2 6 5 Iwo Pipe Multiple Burner System 2 5 2 Installation Checklist 2 11 Starting Up and Operation 3 1 3 1 Preparation for Initial Startup 3 1 3 2 Firing Preparations 3 2 3 2 1 Gas Burners 3 2 3 2 2 Oil Burners 3 2 3 2 3 Oil Flow 3 2 3 2 4 Oil Pressure and Vacuum 3 2 3 2 5 Burner Settings 3 3 3 2 6 Combustion Settings 3 3 3 2 7 Test Equipment 3 3 3 3 Sequence of Operation 3 4 3 4 Electrical Interference Test 3 4 3 4 1 Gas Fired 3 4 3 4 2 Oil Fired 3 4 3 5 Startup and Operating 3 4 3 5 1 Gas Burners 3 4 3 5 1 1
43. h fire at this point using combustion instruments High fire combustion analysis is typically 3 0 to 4 0 05 Verify maximum input rate by measuring the oil meter if available or by weighing the oil The burner should be set up and maintained to yield smoke spot levels less than a 1 spot ASTM D2156 Shell Bacharach Scale to minimize soot buildup in the boiler Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate settings When conditions covered above are assured refer to Sections 3 7 and 3 8 3 6 Combination Gas Oil Burners In general the combination fueled system is to be started first using oil because as a fuel oil has a greater com bustion air requirement than natural gas Refer to the information in Chapter 4 for gas or oil burner adjustment procedures Once the adjustments are set for oil shut down the burner and restart and adjust the natural gas fuel Do not readjust the air shutters The adjustment is made by balancing the fuel input rate against the existing flow of combustion air When conditions covered above are assured refer to Sections 3 7 and 3 8 NOTE Sizes 1 and 2 combination gas oil units use a direct coupling from the blower motor to the oil pump When firing gas for an extended period of time the coupling should be manually removed and replaced only when firing oil If the coupling is left connected to the blower moto
44. he OFF position 2 Close all main fuel lines 3 If the burner operates in a damp environment cover it with plastic to protect all electrical components from moisture 4 Remove the flame safeguard and store in a dry atmosphere IC SA 1249 revised 2011 5 5 K Series Manual Maintenance INDUSTRIAL COMBUSTION 5 10 Maintenance Flow Chart Recommended Test Schedule mem SERWCEB kees DAILY WEEKLY 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 fluctuat ing Check all burner linkages for tightness Tighten if required MONTHLY Manually adjust until the switch opens Low Fan Pressure Interlock Operator High and Low Gas Pressure Inter Operator locks scanner and Diffuser Operator Pilot Assembly Operator ANNUALLY Strainer Oil Units Operator Impeller Operator Combustion Test Service Tech Pilot Turndown Test Service Tech Operating Controls Service Tech Refer to instructions Manually adjust until the switch opens Check inspect and clean for soot buildup Ch
45. her codes piping should be in accordance with the following standards e National Fuel Gas Code NFPA No 54 e ANSI No 2223 1 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 insurance regulation such as Underwriters labo ratories Canadian Underwriters Laboratories UL cUL Factory Mutual or XL GAP See Figures 2 3 through 2 5 for component arrangement Arrange gas piping at the burner so that the burner is accessible for servicing without disassembly The pilot gas train is supplied with the burner and is factory installed The gas pilot supply line must be con nected 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 shutoff valve The gas piping must be internally clean and free of foreign material Before using in service a leak test must be performed see Chapter 3 Section 3 5 2 6 Fuel Oil Piping 2 6 1 Pressure Atomization Oil Piping The KL and KLG model burners use pressure atomization Fuel oil is provided by a burner mounted fuel unit directly coupled to the blower motor via a flexible coupling The suction and return line sizes two pipe system are based on the suction rate of the fuel unit and not the burner firing rate P
46. iagram below when following this procedure The unit should be taken out of service if the unit fails any of the following tests Any defective part must be replaced prior to putting the equipment back into service Failure to follow this procedure may result in explosion fire property damage and serious personal injury or death This procedure must be performed by authorized and gualified personnel only Fig 6 3 CI ee 2 4 5 DE 7 gt 8A Il I A TI I age A sa 1 2 1 2 FIGURE 3 1 Bubble Test Diagram 1 Close or shut off the manual valve 7 downstream of the automatic safety shutoff valves trapping gas pres sure between the safety shutoff valves and the manual valve and causing a flame failure This should close the auxiliary safety shutoff valve 4 and the main gas safety shutoff valve 5 If both or either valve fails to close do not proceed until the problem has been corrected 2 Release gas pressure at the leak test cock 8B between the manual valve 7 and the main gas safety shutoff valve 5 then conduct a bubble test for a leak through the blocking valve 5 If there is no leak close the test cock 3 release gas pressure at the test cock 8A and bubble test for a leak through the auxiliary safety shutoff valve 4 If no leak is observed close the test cock and go to the next step If either valve leaks correct the problem and retest 1O times before proceeding 4 When there are
47. in accordance with the instructions in this manual Allow the boiler to fully warm up before making adjustments for most efficient combustion Refer to the boiler instruction manual for the boiler controls settings 4 8 1 Gas Burners The gas burners adjustments on a full modulation burner consist of the gas pressure regulator butterfly gas valve low and high gas pressure switches and air dampers 1 Open the manual gas shutoff cocks 2 Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator Make sure they are in accordance with the regulator specifications The gas pressure required at the manifold is the pres sure that is required to fire the burner at its rated capacity To adjust the regulator unscrew the cap located on top and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 3 Set the AUTO MANUAL switch to the MANUAL position 4 Position the manual flame control potentiometer in the CLOSED low fire position 5 Turn the burner switch to the ON position The burner will start and be in the low fire position IC SA 1249 revised 2011 4 11 K Series Manual Adjustments INDUSTRIAL COMBUSTION After a few seconds the O analyzer should have an accurate reading of the O present in the flue gas Nor mally Os levels are set between 4 to 6 at low fire with less than 50 ppm CO To obtain the
48. ine 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 should not be energized 3 Upon completion of a successful test proceed with startup procedures 3 4 2 Oil Fired 1 Disconnect the electrical power to the burner Disconnect the electric oil safety shutoff valve Reconnect electric power Close the pilot line manual gas valve if used with just the electrical ignition system energized The flame relay should not pull in Upon completion of a successful test disconnect the power supply 6 Reconnect the oil safety shutoff valve and turn on the manual pilot gas valve 7 Reconnect the power supply and proceed with startup procedures B N m 3 5 Startup and Operating 3 5 1 Gas Burners 3 5 1 1 Performing a Gas Valve Leak Test Bubble Test A gas valve leak test must also 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 auto matic 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 3 4 IC SA 1249 revised 2011 K Series Manual 3 5 Startup and Operating INDUSTRIAL COMBUSTION Refer to the d
49. ing value of the gas in Btu ft contact the local gas company for an exact measure ment Patm Atmospheric pressure in inches of mercury Pgas Gas pressure ahead of the volumetric flow meter in inches of mercury Tgas Gas temperature at the volumetric flow meter in degrees F RATE Natural gas rate taken with the volumetric flow meter in ft second 9 After completing all adjustments replace the regulator gaskets and slotted aluminum screw cap Tighten all linkages and marked settings Complete the Start Up Report IC SA 1249 revised 201 1 4 9 K Series Manual Adjustments INDUSTRIAL COMBUSTION The size 2 KG 30 to 42 use a butterfly gas valve to control the gas flow to the burner The M436 Mod motor controls the position of the valve 1 Open the manual gas shutoff cocks 2 Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator Make sure they are in accordance with the regulator specifications The gas pressure required at the manifold is the pres sure that is required to fire the burner at its rated capacity To adjust the regulator unscrew the cap located on top and turn the adjustment screw clockwise to increase pressure or counterclockwise to decrease pressure 3 Turn the burner switch to the ON position The burner will start and be in the low fire position 4 After a few seconds the O analyzer should have an accurate reading of the O present in the fl
50. ipe size must be selected so that suction vacuum is within suitable limits 2 6 2 Two Pipe Single Burner Operation A two pipe system is essential The suction and return between the storage tank or supply source and the burner must be sized to supply the required quantity of oil circulated including excess oil returned to the storage tank 2 4 IC SA 1249 revised 2011 K Series Manual 2 6 Fuel Oil Piping INDUSTRIAL COMBUSTION 2 6 3 Suction Line Sizing The suction load is determined by 1 The vertical lift from the oil level in the tank to the pump 2 Pressure drop through valves fittings strainers etc 3 he friction loss due to oil flow This loss varies with a quantity of oil pumped gph b length of suction line feet c diameter of the suction line d number of fittings Although the gear type pumps used on the K Series burners are capable of developing higher suction it is not desirable to operate above 15 inches of mercury vacuum If the vacuum is greater flow may be erratic Refer to the manufacturer s table for line sizing 1 Check suction capacity 2 Measure total pipe length horizontal and vertical 3 Read up from the line total feet of copper tube to the intersection line of the specific suction capacity in gph 4 Read left to the column inches of vacuum at fuel unit This is vacuum required to draw oil through pipe listed at given length 5 Add 1 of vacuum f
51. justed shut down the burner 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 emergency open the main power switches and close all fuel valves After combustion adjustments are satisfactorily set allow the heating vessel to slowly reach normal operating pressure or temperature After the boiler has reached operating temperature or pressure turn the potentiometer switch in small incre ments to the high fire position Check high fire at this point using combustion instruments High fire combustion analysis typically is 2 0 to 3 5 O Verify maximum input rate by measuring the gas meter Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate settings CO levels should be less than 50 ppm as the target value When conditions covered above are assured refer to Sections 3 6 and 3 7 3 5 2 Oil Burners 1 Set the fuel selector switch to OIL and the ON OFF switch to the OFF position 2 Actuate the manual reset button of the flame safeguard control to close the safety switch contacts 3 6 IC SA 1249 revised 2011 K Series Manual 3 6 Combination Gas Oil Burners INDUSTRIAL COMBUSTION 3 Set the ON OFF switch to ON The burner will start and pre purge After pre purge the ignition trans former will direct spark If the
52. l L a De LEE oai c Ou V e L IL Jl 03 a Lid i a L0 at eu E I lil O DL MM at T m T it ce lm lu A a e 2 E silt i n aU 2 E E Wi uu aL t3 mi a J O e 2 j un os E ri x e A PACK WITH PLASTIC REFRACTORY EQUAL RAM FROM FRONT TO REAR KAISER MONO T 9 AIR SET OR ZA k l O gt O ox i 0 ta ew E 0 T dE t E Pee Peer Wa Vr ee ee ee ee POR Bre eee taat Ex es OC OC OLG RARA E Mata ete ee ee ee ji ja af COR UR UR UO OX OR OM OR OX OK OO a A F1 Feu NM UM EN UM MN Nd COLO UL UC UM UO OK OG Das eds a t Ja t BOILER FRONT PLATE BURNER FLANGE A COAT BOTH SIDES WITH TROWLEZE SI RR x A P s tit IR lh a ea MR y a D waa ga La aal E E L ES i E 5 b A L a T RE 3 4 ary ick ol all cad OF COAT OUTER CIRCUMFERENCE DRY OVEN WITH TROWLEZE DRY OVEM SUPPLIED WITH BURNER STEEL WRAPPER ON CONE SUPPLIED WITH BURNER GASKET i FIGURE 2 2 Mounting Details for Scotch Marine Boilers IC SA 1249 revised 2011 K Series Manual Installation INDUSTRIAL COMBUSTION 2 5 Gas Piping Gas service and house piping must supply the quantity of gas demanded by the unit at the pressure required 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 ot
53. lly install the drawer assembly into the burner Reconnect the oil line scanner and high voltage power cable to the assembly Measure the position of the diffuser to the air baffle and compare it to the following drawer assembly drawings To adjust 1 Measure the distance between the leading edge of the diffuser and the front face of the inner ring on the air baffle assembly If adjustment is required loosen the burner pipe locking setscrew located on the rear cap at the top of the fan housing and slide the burner pipe until the correct dimension is achieved Tighten the burner pipe locking setscrew securely NOTE Maximum valve inlet pressure for the V4944 is 0 5 psi If line pressure is greater an over pressure device is to be installed downstream of the main gas regulator CSD 1 CF160 IC SA 1249 revised 201 1 4 5 K Series Manual Adjustments INDUSTRIAL COMBUSTION 1 3 8 HOLD DIMENSION FROM NOZZLE TIP TO BACK OF DIFFUSER LOCATE DIFFUSER FACE FLUSH WITH EDGE QF RADIAL GAS HOLES BLAST TUBE WELDMENT REF FIGURE 4 3 Size 1 KL amp KLG 13 to 25 4 HOLD DIMENSION FROM MOZZLE TIP TO BACK OF DIFFUSER LOCATE DIFFUSER FACE FLUSH WITH EDGE OF RADIAL GAS HOLES FIGURE 4 4 Size 2 KL amp KLG 30 to 42 4 6 IC SA 1249 revised 2011 K Series Manual 4 5 Burner Settings INDUSTRIAL COMBUSTION 4 HOLD DIMENSION FROM NDZZLE TIPS
54. ly is clear of the burner head bracket turn the pilot assembly and retract it through the access hole Inspect the electrode and adjust the gap if necessary Thoroughly clean and adjust the porcelain insulated electrodes Correct all variations from the clearance dimensions If the insulation on the high voltage cables becomes cracked or charred install new cables Ignition cables should not be exposed to moisture abrasion or rough handling 10 See that the connectors are in perfect contact with the cable ends by unscrewing the snap portion of the con nector B m N m eo eS N 9 5 Flame Scanner The scanner must be clean Even a small amount of contamination will reduce the flame signal Wipe the scan ner lens with a clean soft cloth Check pilot and flame signal strength 5 8 Burner Mounting Inspection The seal between the burner flange and furnace front plate must not permit combustion gases to escape Peri odic inspection is important If leaking occurs refer to Chapter 2 for proper sealing procedure 5 4 IC SA 1249 revised 2011 K Series Manual 5 9 Extended Shutdown INDUSTRIAL COMBUSTION 5 9 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 lite of the burner 1 Turn the main electrical disconnect switch to t
55. manometer to measure draft pressures Smoke spot tester for oil burners and CO analyzer for gas fired units Voltmeter Ammeter o m m p Stack thermometer and thermocouples Read the flame safeguard manual and fully understand its content before attempting to operate this equipment Fail ure to follow this instruction may result in serious personal injury or death 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 Before re lighting the combustion chamber must be purged IC SA 1249 revised 2011 3 3 K Series Manual Starting Up and Operation INDUSTRIAL COMBUSTION 3 3 Seguence of Operation 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 a the operating and high limit control temperature and pressure are below their cutoff setting p all power supply switches are closed C power is present at the control panel Refer to the manufacturer s literature on programming controls and burner wiring diagrams for detailed informa tion 3 4 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 3 4 1 Gas Fired 1 Close the pilot and main l
56. no valve leaks open the manual valve 7 and re light the burners Then close the manual valve 1 The safety shutoff and blocking valve should close due to low gas pressure 5 Re light the burners Reduce the high gas pressure switch 6 setpoint setting until it reaches the operating gas pressure which should cause the auxiliary and main gas safety shutoff valves to close from high gas pres sure Return the setpoint to its original position before proceeding e Shut off the combustion air blower This should cause a failure due to low air pressure and cause the safety valves to close IC SA 1249 revised 201 1 3 5 K Series Manual Starting Up and Operation INDUSTRIAL COMBUSTION 7 Reset all manual valves to their normal setting for operation Make sure all electric valves are operating nor mally Make sure all test cocks are closed before resuming normal operation 3 5 1 2 Initial Startup 1 Close the downstream main and pilot gas cocks Make sure the ON OFF switch is in the OFF position Actuate the manual reset button of the flame safeguard control to close the safety switch contacts For Low High Off or Low High Low and Full Modulation models set the MANUAL AUTO switch to the MANUAL position 2 Set the manual potentiometer to the low Tire position 3 Open the gas pilot cock and check the pressure A normal setting is 3 to 6 WC when the pilot is burning 4 Set the ON OFF switch
57. op in gas pressure 8 Interlock device inoperative or defective 9 Air in the oil lines Bleed lines Modulating Motor Does 1 Manual automatic switch in wrong position Not Operate 2 Linkage loose or jammed 3 Motor does not drive to open or close during pre purge or close on burner shutdown a Motor defective b Loose electrical connection c Damper motor transformer defective 4 Motor does not operate on demand a Manual automatic switch in wrong position b Modulating control improperly set or inoperative c Motor defective d Loose electrical connection e Damper motor transformer defective IC SA 1249 revised 2011 6 5 K Series Manual INDUSTRIAL COMBUSTION Troubleshooting 6 6 IC SA 1249 revised 2011 K Series Manual 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 Burner Model Serial Number Startup Date Electric Motors L1 L2 Control Voltage 1 Seer compresor ESL Air Oil or Metering Lo W 76 76 HEN A IO Loewenws TTT re tiie Stack Temp Interlock CO PPM NOx PPM EB Flame Failure EN 2 Combustion Air Switch m EN ue um m EE NE AR e AE E uu MM E MN EE NE NE O Stack Draft W C Furnace Pressure W C i
58. operating controls require very little maintenance beyond regular inspection Examine electrical connec tions 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 1249 revised 2011 5 1 K Series Manual Maintenance INDUSTRIAL COMBUSTION When replacing a control or cleaning contacts be sure to disconnect the main power supply since the control is ener gized even though the burner switch is off More than one disconnect switch may be reguired to disconnect all power 5 2 1 Programming Control This control reguires no adjustment nor should any attempt be made to alter contact settings or timing logic Those programmers with contacts may reguire occasional cleaning If so follow instructions given in the manu facturer s bulletin Never use abrasive materials The manufacturer s bulletin also contains troubleshooting infor mation 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 ver ify safety shutdown with a safety lockout upon failure to ignite
59. or replace BUT NOT INSTALL F O 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 sub paragraph 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 30 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 required by the Company to be defective within this part war ranty The warranty and warranty period for spare and re
60. or every foot of lift 6 Total inches of vacuum frictional tube loss plus lift 7 If total exceeds 15 check next larger pipe size 2 6 4 Return Line Sizing Generally the return line should be sized the same as the suction line 2 6 5 Two Pipe Multiple Burner System Several options exist for a multiple burner installation In Figure 2 9 a typical installation showing separate suc tion lines for each burner with a common return line Figure 2 10 shows multiple burners with oil supplied by a transfer pump The circulating pump is sized in this case for the total suction capacity of all burners Note that a special pressure regulating valve is required if the fuel unit inlet pressure is above 3 psi Figure 2 11 shows an installation using a day tank A pump supplies oil to the day tank Figure 2 12 shows a flooded loop system The circulating pump is sized according to the maximum burner firing rate for all burners plus a 3076 service factor The burner return lines feed into the common supply line NOTE Industrial Combustion recommends that all oil firing burners be equipped with an oil strainer if not included with the burner to prevent particles from clogging the nozzle It is essential to follow the strainer manufacturer s maintenance schedule to ensure proper filtration IC SA 1249 revised 201 1 2 5 K Series Manual INDUSTRIAL COMBUSTION Installation OUTPUT TO BURNER i L REGULATOR ve GAS s
61. pecifications Do not use gasoline crankcase oil or any oil containing gasoline K Series Specifications REMOTE GAS BURNER GASINPUT keetis Es MOTOR MOTOR OIL PUMP GGR VOLES PRESSURE MODEL MBH P i HP HP MOTOR REQUIRED WC EFF ape PURSE WC jac a ue es o o og 9 po Lom ee Mem a ano ws es fo po poem os Me 2 soe m as m Da aom ose Mew s sen pm o fm 2 e eme es Mes s eme ws o om 3 a meme 08 Mew s sme me so a o meme aon me vom mr m m e emen ase Meus umm oor m wo pn ie nemen me pases eem en m Te ee NOTES Gas input based on natural gas at 1 000 BTU cu ft and 0 60 gravity Gas pressure based on zero furnace pressure For total pressure at manifold add furnace pressure Oil input based on No 2 Oil at 140 000 BTU gal Boiler overall efficiency of 80 estimated Blower motor HP is based on altitude up to 2 000 ft above sea level For higher altitude or 50hz applications consult factory Firing at higher furnace pressures de rates the burner by approximately 5 per 1 2 of additional pressure consult factory MOTOR SELECTION 1 Motor ratings for gas only and remote oil pump burners 2 Motor ratings for direct drive oil pump burners 3 Remote oil pump is optional for frame size 1 2 For frame size 3 4 remote oil pump is standard INDUSTRIAL COMBUSTION INDUSTRIAL COMBUSTION K Series Table o
62. placement parts not manufactured by the company pur chased 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 extensive warranty obligations of the Company to the Buyer for such parts than the IC SA 1249 revised 2011 K Series Manual INDUSTRIAL COMBUSTION 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 equipment THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEQUENTIAL 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 installation or use of the equipment IC SA 1249 revised 2011 K Series Manual
63. r ensure that there is proper oil circulation at all times to avoid damage and seizure of the pump IC SA 1249 revised 201 1 3 7 K Series Manual Starting Up and Operation INDUSTRIAL COMBUSTION ACCESS COVER BLOWER MOTOR FLEXIBLE COUPLING FIGURE 3 2 Flexible Coupling Location 3 7 Normal Operation Normal operation must be with the MANUAL AUTO switch selector on AUTO In automatic operation the operating cycle always proceeds seguentially through pre purge pilot ignition main flame ignition run and post purge The length of purge and ignition trial vary according to the type of program mer 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 the burner is initially placed into service when a control is replaced and at scheduled intervals in the maintenance pro gram Refer to adjustment procedures and maintenance instructions provided in Chapters 4 and 5 3 8 IC SA 1249 revised 2011 K Series Manual 3 8 Shutdown INDUSTRIAL COMBUSTION 3 8 Shutdown When the operating limit control setting is reached or the burner switch is turned OFF the following seguence OCCUIS
64. r performance the location and gap setting of the electrodes and the relative positions of the burner nozzle diffuser and air baffle components must be set correctly These items are preset at the factory but must be checked prior to placing the burner into initial service or after conducting any service work that may have altered their position The nozzle diffuser assembly must be removed from inside the burner to enable measurement and adjustment To remove 1 Lockout and tag the electrical power supply to the burner to prevent inadvertent operation during checkout or maintenance activities 2 Disconnect the high voltage power supply from the oil spark ignition electrodes if installed 3 Disconnect the flame scanner and oil piping from the end of the blast tube 4 Remove the fasteners that secure the drawer to the side of the fan housing and remove the complete assem bly For burners with a gas pilot 1 Disconnect the pilot line and loosen the locking screws on the pilot access cover located on the side of the blast tube 2 Disconnect the high voltage ignition cable by pulling it straight back away from the pilot assembly The pilot assembly will slide back and away from the diffuser 3 urn the assembly and retract it through the access hole 4 Check the electrode position as illustrated in Size 1 amp 2 Gas Pilot Figu re 4 1 CENTER ELECTRODE IN OPENING ELECTRODE FLUSH W END OF TUBE 8 3 4 5
65. re energized open Flame Failure red Illuminates when the flame safeguard system fails to detect pilot or main flame 7 Modulating Motor Operates the air damper and fuel rate valves through a linkage system to adjust air fuel ratios under all load conditions 8 Ignition Transformer Provides high voltage spark for ignition of gas pilot or main flame direct Spark models 1 4 Flame Safeguard Controls The flame safeguard controls the operating sequence of the combustion system pre purge pilot firing and shutdown 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 as shown in the manufacturer s flame safeguard manual 1 2 IC SA 1249 revised 2011 K Series Manual 1 5 Combustion Air Handling System INDUSTRIAL COMBUSTION 1 5 Combustion Air Handling System Component Description 1 Motor and Blower The impeller is directly driven by the motor at 3450 rpm Combustion air is supplied by a heavy duty balanced backward curved impeller The impeller remains free from dirt accumulation 2 Air Volume Regulator The air damper is located in the air inlet housing Low High Off Low High Low or Full Modulation burners have the damper directly driven by the modulating motor 3 Combustion Air Proving Switch A pressure sensitive switch actua
66. re to do so may result in serious personal injury or death Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments Failure to do so may result in serious personal injury or death Do not re light the pilot or attempt to start the main burner either oil or gas if the combustion chamber is hot and or if gas or oil vapor combustion gases are present in the furnace or flue passages or when excess oil has accumulated Promptly correct any conditions causing leakage Failure to do so may result in serious personal injury or death 6 2 Emergency Shutdown In case of emergency shut down the burner by turning the ON OFF switch to the OFF position Turn the fuel selector switch to the OFF position Shut off the main manual fuel shutoff valves on the fuel supply line The unit can also be shut down with the main electrical power disconnect Inspect the burner carefully and trouble shoot before restarting the unit Follow the instructions in Chapter 3 for starting and operating 6 2 IC SA 1249 revised 2011 K Series Manual 6 3 Troubleshooting INDUSTRIAL COMBUSTION 6 3 Troubleshooting Possible Causes Burner Does Not Start 1 No voltage at the program relay power input terminals a Main disconnect switch open b Blown control circuit fuse c Loose or broken electrical connection 2 Program relay safety switch requires resetting 3 Limit
67. rmally open N O solenoid valves are part of the oil system on Low High Off and Low High Low burn ers The two N C valves provide positive shutoff of fuel oil while the one N O valve cycles the burner to high fire when closed 5 Oil Metering Valve The firing rate is controlled by an adjustable metering valve in the return line At low fire the metering valve is open and is closed at high fire 6 Oil Filter Prevents foreign matter from entering the burner oil system This item is pro vided as an option and shipped loose with the burner IC SA 1249 revised 201 1 1 3 K Series Manual Introduction INDUSTRIAL COMBUSTION 1 6 1 Operation Fuel is delivered to the fuel unit either by gravity fuel unit suction or by a circulating pump through a fuel oil filter Pressurized fuel returns to the storage tank until the two solenoid valves open On direct spark ignited burn ers KL13 42 ignition occurs when the oil valves open Where gas pilots are provided models KG and KLG the oil valves open after the pilot is proven Oil input rate is controlled by the oil metering valve which varies the flow to meet load demands The low fire positions bypass oil back to the storage tank At high fire the metering valve is in the closed position The modulating motor positions the metering valve and the air damper simultane ously 1 7 Pilot System Oil only models KL13 42 are supplied with direct spark ignition Models KL54
68. rther adjustment after instal lation 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 mis adjust ments occurred during shipment and installation A combustion efficiency analysis made during the initial startup will help to determine what additional adjust ments are required in a particular installation 4 2 Combustion Adjustment on Oil and Gas Efficient combustion cannot be properly judged by flame appearance although it may help in making 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 CO5 oxygen 02 and carbon monoxide CO At no time should CO measurements alone be used to indicate proper excess air levels Only O measurement can definitively show whether sufficient air has been provided for combustion 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 Decreasing either the temperature or the volume of the flue gas or both can reduce stack heat loss Flue gas temperature is reduced by improving
69. sing that contains the regulator adjustment setscrew Turn the adjustment setscrew clockwise to increase the pressure or counterclockwise to decrease the pressure setting Allow enough time for the pressure to reach equilibrium between pressure adjustment 6 After a few seconds the 05 analyzer should have an accurate reading of the 05 present in the flue gas Nor mally Os levels are set between 4 to 6 at low fire with less than 50 ppm CO To obtain the proper read ings adjust the air shutter and low fire regulator pressure 7 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water s Bring the burner to the high fire position and adjust the regulator pressure Adjust the high fire gas input to match maximum rating Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate Verify and record your readings and pressures High fire is typically 2 to 4 05 with less than 50 ppm CO The burner should be adjusted to provide correct fuel flow at a constant rate at the low fire and high fire posi tion as indicated on the burner data plate This is achieved by clocking the gas flow at the gas meter The gas utility or gas meter calibration data should be consulted to determine the correction factors to be applied to the meter i 3 Gas Input HHV x Patm Pgas x 520 x 3600 x nare ft Btu 29 92 Tgas 460 hr s hr HHV The higher heat
70. spot ASTM D2156 Shell Bacharach Scale to minimize soot buildup in the boiler 4 3 Gas Pilot Flame Adjustment Burner models KG KLG and KL 54 to 145 are equipped with a gas pilot system The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator A normal setting is 3 to 6 WC 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 The flame safeguard amplifier has a meter jack for this purpose At initial startup and during planned mainte nance test the pilot flame signal pilot turndown and safety switch lockout Refer to the flame safeguard instruc tion manual An ultra violet flame sensor electrical spark interference test must be performed after final adjustment See Chapter 3 for additional information Check the pilot electrode setting The pilot is accessible by loosening the four screws on the side of the blast tube and disconnecting the gas line IC SA 1249 revised 201 1 4 3 K Series Manual Adjustments INDUSTRIAL COMBUSTION 4 4 Direct Spark Oil Pilot Adjustment Burner models KL 13 to 42 are eguipped with a direct spark ignition Remove the oil drawer assembly and check the electrode settings and nozzle size 4 5 Burner Settings To ensure reliable and sate burne
71. ted by air pressure created by the blower fan Contacts close to prove combustion air flow 1 5 1 Operation Air from the impeller flows through the blast tube and baffle to mix with fuel in the ignition zone Combustion air flow rate is determined by the position of the air regulating blades at the inlet of the impeller Linking the air flow with fuel flow provides efficient combustion at all firing rates 1 6 Oil System Models KL KLG are high pressure atomizing burners using fuel pressure for atomization Atomized fuel is dis charged from the nozzle as a fine conical spray 1 Fuel Unit Direct driven from the blower motor with a flexible coupling at 3450 rpm and set for 300 psi operation the fuel unit is two stage two sets of gears and must be installed for a two pipe installation one suction and one return line Separately driven oil pumps are available as an option to the standard arrangement 2 Nozzle The nozzle meters oil flow delivering a specified amount at a specific pres sure Fuel pressure mechanical atomizes oil in a fine conical spray pattern from the nozzle orifice The burner is supplied with nozzle s to fire to its maximum rate unless a different firing rate was specified Return flow noz zle s are used on the full modulation burners 3 Nozzle Adaptor The nozzle adaptor provides the the means for connecting fuel lines with the nozzle 4 Oil Solenoid Valves Two normally closed N C valves and one no
72. 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 con tained in the manufacturer s bulletin 5 2 2 Motors Supply voltage to the motor must not vary more than 10 from nameplate ratings At initial startup and regu larly thereafter check the motor current with an ammeter while the burner is in high fire position If the reading exceeds the nameplate rating plus service factor determine the cause and correct it In dusty locations clean the motor regularly to assure adequate cooling Lubricate in accordance with the manufacturer s instructions 5 3 Gas System Check the gas train for leaks Check the gas valves and verify the low and high gas pressure settings 5 3 1 Solenoid Valves A faint 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 the 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 the manufacturer s bul letin for correct coil replacement procedures should it become necessary to replace the complete valve be sure that the flow is in the direction of the arrow on the valve body Test for gas leaks and check valve action several times to ensure proper operation before attempting to relight the burner
73. tion To check for proper pump rotation momentarily energize the starter With rotation verified operate the pump to determine that oil circulation is present Observe the oil burner pressure gauge If no pressure shows after a few moments stop the oil pump and re prime If the supply tank is lower than the pump it is possible that the initial priming of the suction line followed by operation of the pump will not establish oil flow This might be caused by an obstruction in the suction line excessive lift inadequate priming suction line leaks etc Until oil flow is established avoid prolonged operation of the pump If oil flow is not established after a second priming investi gation Is required A vacuum or compound pressure vacuum gauge should be installed at the suction port of the pump It is advis able that the reading be less than 15 Hg vacuum Vacuum in excess of this may cause unstable firing 3 2 4 Oil Pressure and Vacuum If the vacuum gauge reads higher than calculated look for restriction in the suction line a closed valve kinked copper tubing plugged filter sticking check valve frozen oil line undersized oil line or excessive lift 3 2 IC SA 1249 revised 2011 K Series Manual 3 2 Firing Preparations INDUSTRIAL COMBUSTION When there is a positive head of oil at the fuel unit either from a gravity or by pump circulation the pressure must not exceed 3 psi at the fuel unit suction inlet
74. to be started first using oil because as a fuel oil has a greater com bustion air requirement than natural gas After being completely adjusted for oil combustion the burner is re started and adjusted using natural gas as fuel Combustion adjustment of the combination burner for natural gas involves balancing the input rate only against the existing flow of combustion air as established initially for oil NOTE Do not readjust the air shutters when turning the combination burner for combustion of natural gas 1 Set the MANUAL AUTO switch to MANUAL 2 Position the manual flame control potentiometer in the CLOSED low fire position 3 Turn the fuel selector switch to the OIL position 4 Proceed with startup and adjustments using the same procedures defined in Section4 8 2 5 After the system has been completely adjusted for oil firing turn the burner switch OFF and position the fuel selector switch to GAS 6 Proceed with startup and adjustments using the same procedures defined in Section 4 8 1 Do not alter the air setting set for oil Correct the Os levels by adjusting the butterfly valve IC SA 1249 revised 2011 4 13 K Series Manual Adjustments INDUSTRIAL COMBUSTION TYPICAL LOCATION OF THE POINTER WHEN AT HIGH FIRE MAIN AIR SHUTTER SHOWN IN LOW FIRE POSTION HIGH FIRE AIR SHUTTER W INDICATOR LOW FIRE AIR SHUTTER W INDICATOR FIGURE 4 7 Shutt
75. ue gas Nor mally Os levels are set between 4 to 6 at low fire with less than 50 ppm CO To obtain the proper read ings adjust the gas butterfly opening and air shutter Take note of the readings and pressures at the burner manifold and gas train 5 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water 6 Bring the burner to the high fire position Adjust the high fire gas input to match maximum rating At high fire the butterfly valve should be near the full open position Adjust the gas regulator so the manifold pressure matches the rating on the burner data plate Verify and record your readings and pressures High fire is typi cally 2 to 4 05 with less than 50 ppm CO 7 Adjust the low and high gas pressure switches by turning the adjusting screw until the indicator moves to a pressure slightly lower than normal operating pressure for the low gas pressure switch and slightly higher for the high gas pressure switch usually 20 below and 20 higher than normal pressure 8 Verify low fire and high fire rate by clocking the meter as previously explained 4 7 2 Oil Burners The Suntec B2TD 8842 oil pump is typically incorporated and is a two stage two step oil pump The low fire pressure adjustment is 100 to 200 psi solenoid de energized High fire pressure adjustment is 200 to 300 psi solenoid energized 1 Turn the burner switch to the ON position 2 Adjust low fir
76. uel lines IC SA 1249 revised 2011 5 3 K Series Manual Maintenance INDUSTRIAL COMBUSTION 5 6 Ignition Electrode Cable and Pilot Failure to keep electrodes clean and set in the proper position accounts for much faulty burner operation Not only must the gap be correct but the electrode points must be carefully located with respect to the nozzle sometimes difficulty in securing the electrodes in their clamps can be corrected by using light metal shims around the porcelain Defective or cracked porcelains require replacement to prevent short circuiting of the spark A gradual wearing away of the electrode tips may require re spacing of the points or replacement of the electrode The pilot should be checked monthly for loosening of components and carbon buildup Before removing the pilot ensure that the fuel supply is shut off On direct spark oil units once the drawer assembly has been removed check the electrode to nozzle gap and adjust if necessary Refer to the drawer assembly drawings in Chapter 4 For burners equipped with a gas pilot the pilot is located on the side opposite to the main gas entrance 1 Close the gas pilot cock Disconnect the pilot gas supply line Remove the screws on the pilot access plate Disconnect the high voltage ignition cable by pulling it straight back away from the pilot assembly The pilot gun assembly will slide back away from the flame side of the burner Once the pilot assemb
77. utters the firing rate is regulated by a metering valve in the nozzle return line At low fire the arrow on the valve points to approximately number 7 and at high fire it is in the closed position no return flow approximately at number 2 The oil metering valve position will vary the oil pressure to the nozzle An oil pressure gauge should be installed in the return line to 4 12 IC SA 1249 revised 2011 K Series Manual 4 8 Full Modulation Burner Adjustments INDUSTRIAL COMBUSTION monitor the oil pressure Oil pressure at low fire is approximately 80 psi to 100 psi and 300 psi at high fire Size 1 2 and k K burners use a simplex nozzle Size 4 K burners use a return flow nozzle 1 Set the MANUAL AUTO switch in the MANUAL position set the manual flame control potentiometer in the CLOSED low fire position Turn the burner switch to the ON position The burner will start and be in low fire Adjust low fire with the metering valve position to have approximately 80 psi to 90 psi and adjust the low fire air shutter for a clean fire Record the combustion reading from the flue gas analyzer normally 8 to 11 CO and less than No 2 Smoke Bacharach 5 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water Then increase the fuel input to the boiler by turning the manual flame control potentiometer towards OPEN in small increments This will cause th
78. ve the setting the switch contacts will open causing main gas valve s to close This switch requires manual reset after being tripped 6 Low Gas Pressure Switch A pressure actuated switch that remains closed when gas pressure is above Models 25 145 a 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 1249 revised 2011 K Series Manual 1 8 Gas Handling System INDUSTRIAL COMBUSTION 1 8 1 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 but terfly valve is positioned through mechanical linkage by the modulating motor The air control damper is posi tioned simultaneously by the modulating motor 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 closed 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 NOTE Gas train components upstream of the butterfly valve

IC-SA-1249 K Series Manual 3-2011

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