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IC-SA-1511 V Manual 02-2014

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1. 3SN OS 3AD8V 471 1 9 ASN 08 JADY dn 3ZIS AN T 9 ASN 08 3ABDGV dn e JAZIS AN1 SIN3H3NIDO3S 9 ASN 08 3ADSV dn T 3ZIS AN T 39vdS LINS OL 371 ONIdId 9 74 113 9NIdId 3 9 4 13000 Ov HOS INANE 0413 13 Sniava SNOT AAWA 4sDLNHS ONINOILISOd 3B8343Bd FIGURE 7 6 Temperature Interlocks 7 6 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 represented 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 competent 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 manufacturer s warranty to the Company In no event shall such other manufacturer s warranty create any more extensive warranty obligations of the Company to the Buyer than the Company s warranty covering equipment manufactured by the Company Exclusions From Warranty I THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES ORAL OR EXPRESS OR IMPLIED INCLUDING ANY WARRANTIES THAT EXTEND BEYOND THE
2. 4 8 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 15 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 12 Drawer Assembly for VLG Gas Oil V120 168 Firetube 4 4 6 Drawer Assemblies for Watertube Cast Iron Boiler Applications 1 83 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10215 000 FIGURE 4 13 Drawer Assembly for VG Gas Only V13 34 Watertube Cast Iron IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 5 32 BETWEEN INNER EDGES OF ELECTRODE WIRES 7 16 FROM CENTER OF OIL NOZZLE TIP TO BOTTOM EDGE OF ELECTRODE WIRES 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 1 89 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4 14 Drawer Assembly for VL Oil Only V13 34 Watertube Cast Iron 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 1 83 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4 15 Drawer Assembly for VLG Gas Oil V13 34 Watertube Cast Iron 656 10215 000 1 81 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10215 000 FIGURE 4 16 Drawer Assembly for VG Gas Only V35 55 Watertube Cast I
3. Air Oil or Metering Control Check Test Set Point Test Conducted Low 50 High Low 50 High Low Water Cutoff Firing Rate MMBtu gph Aux LWCO Stack Temp gross F High Water Cutoff Room Temp F Operating Limit 02 High Limit CO Operating Control CO PPM Stack Temp Interlock NOx PPM Flame Failure Smoke Bacharach Combustion Air Switch Combustion Eff Stack Draft W C High Purge Switch Low Fire Interlock Oil Pressure Switch Oil Valve w P O C Interlock Furnace Pressure W C Blast Tube Pressure W C Steam Pressure PSIG Water Temp F High Gas Pressure Switch Supply Oil Pressure PSIG Low Gas Pressure Switch Return Oil Pressure PSIG Gas Valve P O C Interlock Vacuum Oil Pump HG Pilot Turndown Test Oil Temp Flame Signal Pilot Atom Air Pressure For Low NOx Burners Gas Pressure Burner nner Manifold Manifold W C Blast Tube Temp Interlock Outer Manifold FGR Line Purge Switch Center Gas Pressure W C FGR Valve Gas Pressure Regulator Inlet PSIG Gas Pressure Regulator Outlet PSIG Pilot Gas Pressure Regulator Outlet W C Flame Signal Main Low 50 High Adjusted by Date Accepted by Signature Required
4. IC SA 1511 02 2014 7 5 V LNV Series Manual LNV Series FGR System INDUSTRIAL COMBUSTION NOILVINSNI 30 30 WOWINIW V HLIM 383 05 38 SNIdId 3 27 34 TIY 034 3990 SI LI 03310033 sv 1409915 ONIdId 494 3LUN 3910H29 3S3HL NI NOILISOd WOILSSA JHL NI 1 LON SI SOLOW 1 SHL LVHL 31UN 3799193999 SI NMOHS NOILVOO1 338343Md JHL N3HM SAWA AAOLNHS N 9 4 SNINOILISOd 03 3 10 CWNOILdO gt 3a vadW3l 15918 0915 700 4391 LYOHS CIWNOT1d0 gt 110535 TIIM SOLOW 3Hl 01 39VWVG CLJVHS ADLOW COW SHL 30 SIXV JHL A8 GANI43C SI WOILNFAD ATIWOILSSA GALNNOW 38 LON NYI OLOW JdUSInGON 3Hl iNOTLTSOd STHL NI G aLNNOW 38 N3A3N GINOHS FATWA 4SOLNHS 3 3Hl NINSIVM a3Neng ONISNOH ONINSdO 304 318V3AUW33 NELLIS 3919 39 713 LYOHS qasinoaa sv lafddns ONIdId wg LAINI SVO NIVW IC SA 1511 02 2014 V LNV Series Manual SAWA US1ND3 ONIdId 8 9 Ed Or HOS WOWINIW_
5. 2 17 INDUSTRIAL COMBUSTION Installation FULL MODULATION LOW or 60 DAMPER PURGE A two blade damper is controlled by proportional modulating actuator or motor with mechanical linkage The actuator is capable of stopping at any point along its 90 degree stroke based on a signal from a remotely connected modulating control or from a burner mounted manual potentiometer selected by an auto manual selector switch The actuator also contains an internal switch that ensures the damper is in low fire position before ignition is initiated For 60 damper purge a mechanical stop is provided on the damper to ensure sufficient air flow is provided during pre purge COMPONENTS DESCRIPTION Damper is in its closed or low fire position For 60 damper purge PRE PURGE this would be against the Damper remains in it s low fire starting position The burner is now ready for startup STARTUP IGNITION Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an in rush of gas A butterfly type gas metering valve is_ linked directly to the damper actuator and provides gas flow metering relative to the actuators position A manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the
6. LOW HIGH MODULATION OIL RETURN OIL INLET 2 16 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION LOW HIGH LOW MOD OPEN DAMPER PURGE COMPONENTS DESCRIPTION PRE PURGE STARTUP IGNITION RUN MODULATE Operating Sequence Combustion Air A two blade damper is controlled by a two position spring return actuator with mechanical linkage Power to drive the actuator is routed through a low auto switch and a_ remote located modulating control The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system see oil at right A second external switch ensures the damper has returned to the low fire position before ignition is initiated From its closed position the damper is driven open by the flame safeguard control where it remains for the duration of the pre purge cycle Damper returns to the low fire position which is proven through the external switch The burner is now ready for startup Damper is driven open in 30 Seconds by the two position actuator Low High Low burners will modulate from low to high rate positions based on the signal from the modulating control and the selection of the low auto switch Gas Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve which have delayed opening rates to
7. Burner Stays in Pressure or temperature above modulating control setting Low Fire Manual automatic switch in wrong position Inoperative modulating motor Defective modulating control Binding or loose linkages cams setscrews etc Shutdown Occurs During Loss or stoppage of fuel supply Firing Defective fuel valve loose electrical connection Flame detector weak or defective Scanner lens dirty or sight tube obstructed If the programmer lockout switch has not tripped check the limit circuit for an opened safety control oO BR Ww PM gt OH BRB Ww a A 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 drop in gas pressure 8 Interlock device inoperative or defective 9 Air in the oil lines Bleed lines 6 4 IC SA 1511 02 2014 V LNV Series Manual 6 3 Troubleshooting INDUSTRIAL COMBUSTION Problem Possible Causes Modulating Motor Does 1 Manual automatic switch in wrong
8. 100 6 36 17 18 46 83 105 6 36 17 18 46 83 110 6 36 18 18 46 83 120 6 43 19 19 53 120 126 6 43 19 19 53 120 147 6 43 20 19 53 120 168 6 43 22 19 53 120 IC SA 1511 02 2014 2 3 V LNV Series Manual Installation INDUSTRIAL COMBUSTION 2 4 3 Combustion Chamber Drawings Watertube Cast Iron Boiler Application s s 00 9000 05 SX 5 x 5 RX 5 5 os 9 5 Mata NS K C MIN STANDARD FIREBRICK BLOCK INSULATION C MIN STANDARD FIREBRICK FLOOR t 0500 nte te 000 lt 909999 SENS ERY 0200030920200 I ION I HNN KY ed KKH BLOCK INSULATION FIGURE 2 4 Inverted Configuration for Watertube Cast Iron Boiler 2 4 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION 2 4 4 Combustion Chamber Dimensions Inverted Standard Config Watertube Cast Iron Boiler Combustion Combustion Burner Chamber Chamber Model A B Min Width Min Length 13 15 28 26 36 15 15 28 17 15 28 20 15 28 21 15 28 25 15 28 30 15 28 34 15 28 35 21 31 40 21 31 42 21 31 45 21 31 50 21 31 54 21 31 55 21 31 60 21 36 63 21 36 70 21 36
9. 80 21 36 84 21 36 90 21 36 100 21 36 105 21 36 110 21 36 120 21 43 126 21 43 147 21 43 168 21 43 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION Refer to pages 2 2 through 2 5 for combustion chamber dimensions for firetube and watertube boiler applications Combustion chamber dimensions should be adequately sized to prevent flame impingements A dry oven refractory is required only to protect surfaces not adequately protected by free circulating water Basic objectives include Provide adequate combustion space e Avoid flame impingement e Protect surfaces not adequately water cooled Seal openings The chamber dimensions listed on the following pages 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 refractory and the boiler base Mineral wool or other material not likely to settle is preferred The chamber front wall may be constructed of firebrick or insulating firebrick Insulation should be used between the refractory and front plate Firebrick or insulating firebrick should be set in high temperature bonding mortar with provision for expansion N Caution The gasket must be resilient to seal any uneven ar
10. Low NOx Full Modulation Combination Gas Oil Burner Adjustment LNV burners are equipped with an FGR valve to lower the NOx emissions An adjustable cam is provided to adjust the FGR valve position throughout the firing range on gas Follow the steps for gas from Section 4 4 12 with the following additions 1 Make sure the FGR valve is in the nearly closed position 2 Start the burner and hold at low fire until the boiler is at the proper operating pressure or temperature 3 With an analyzer in the stack adjust the FGR valve cam screw to obtain 30 ppm NOXx levels NOTE Do not adjust the burner below 20 ppm Unstable combustion and high CO emissions will result 4 Monitor and CO levels during this process The introduction of FGR into the combustion chamber will lower the flue levels Too much FGR may induce high levels of CO in the flue gas It may be necessary to adjust the air damper blades to raise the to proper low fire values If the proper NOx values can not be reached by adjusting the cam screw the FGR linkage will have to be adjusted as well Once the low fire setting is complete continue with the instructions above adjusting the cam at each screw to obtain the proper NOx values Verify the values modulating back to low fire and adjust accordingly MODULATING MOTOR FGR CONTROL VALVE 656 10219 000 FIGURE 7 4 FGR Control Valve Low Fire Position 7 4 IC SA 1511 02 2014 V LNV
11. Remove the fasteners that secure the drawer to the side of the burner housing and remove the complete assembly 4 4 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 5 For burners with a gas pilot a Disconnect the pilot line and loosen the locking screws on the pilot access cover located on the side of the firing head b 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 c Turn the assembly and retract it through the access hole d Check the electrode position as shown in Figure 4 2 e Re assemble in reverse order ELECTRODE END TIP TO TUBE WITHIN 1 00 GAP OF 16 TUBE END 14 18 656 10213 000 FIGURE 4 2 Gas Pilot Measure the position of the tip of the nozzle to the diffuser and compare it to the drawer assembly drawings in section 4 4 5 for firetube applications and 4 4 6 for watertube or cast iron applications 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 obtained Tighten the diffuser clamp securely to the burner pipe Apply a lock tight type compound to the screws before tightening Carefully install the drawer assembly into the burner Reconnect the oil line and high voltage power cable to the assembly Measure the position of the
12. S SAFETY S Options are available for 4 20mA Ve NOZZLE modulating signal conversion or D D D 4 20 proportional modulating VARIATIONS actuators Also optional is an None actuator with dual low fire start switch positions for improved turn M _ down in dual fuel situations 3 Dl FULL MODULATION gt OIL RETURN WITH SIMPLEX NOZZLE 4 OIL INLET IC SA 1511 02 2014 2 19 V LNV Series Manual INDUSTRIAL COMBUSTION Installation FULL MODULATION OPEN DAMPER PURGE COMPONENTS DESCRIPTION PRE PURGE STARTUP IGNITION RUN MODULATE Operating Sequence SHUT DOWN POST PURGE Combustion Air A two blade damper is controlled by a proportional modulating actuator or motor with mechanical linkage The modulating actuator is capable of stopping at any point along its 90 degree stroke based on a signal from a remotely connected modulating control or from a burner mounted manual potentiometer which is selected through an auto manual modulation selector switch The actuator also contains two internal Switches that ensure the damper reach the high fire and low fire positions during purge and before ignition is initiated From its closed position the damper is driven open by a signal from the flame safeguard control where the high fire air switch is proven The damper will remain open for the duration of the Damper returns to the low fire position which is proven through the internal
13. The control should be adjusted to prevent operation with excessive gas pressure but not at a pressure so close to normal operating pressure that unnecessary shutdowns occur This switch must be manually reset after tripping To reset allow gas pressure to drop and press the manual reset button 4 5 6 Gas Combustion Adjustment After operating for a sufficient period of time to assure a warm boiler make adjustments for most efficient combustion The butterfly gas valve directly controls the rate of flow The low fire light off setting should be regarded as preliminary until proper gas pressure for high fire operation is established Determine the actual gas flow from a meter reading at high fire With the butterfly valve open and with regulated gas pressure set the actual flow rate should be quite close to the required input If corrections are necessary increase or decrease the gas pressure by adjusting the gas pressure regulator following manufacturer s directions for regulator adjustment When proper gas flow is obtained take a flue gas analysis reading With the high fire air fuel ratio established the gas pressure regulator needs no further adjusting Recheck low fire and adjust if necessary Proper setting of the air fuel ratios at all rates must be determined by combustion analysis See Section 4 2 of this chapter for additional information NOTE Check for CO through the entire firing range 4 5 7 On Off Gas Burner Adj
14. burner must be sized to supply the required quantity of oil circulated including excess oil returned to the storage tank 2 7 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 The 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 V 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 NOTE Refer to the manufacturer s table for line sizing If further assistance is required consult factory 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 for 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 7 4 Return Line Sizing Generally the return line should be sized the same as the suction line 2 8 IC SA 1511 0
15. 16 TUBE END 14 18 656 10213 000 FIGURE 1 14 Gas Pilot 1 7 3 Operation Metered gas flows through the main gas shutoff cock through the pressure regulator to the automatic gas valves and butterfly valve to the gas manifold The butterfly gas valve modulates flow to burner demand The butterfly valve is positioned through mechanical linkage by the modulating motor The air control damper is positioned 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 IC SA 1511 02 2014 1 13 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 2 Installation 2 1 Application Electrical power available is usually 115 volt 1 phase 208 volt 3 phase 60 cycle 230 460 volt 3 phase 60 cycle or 380 volt 3 phase 50 cycle Control circuit is 115 volt single phase 60 cycle or 115 volt single phase 50 cycle Refer to the electrical schematic diagram shipped with the burner Power connections are made at the control panel Wiring from the panel to burner mounted components is installed
16. 2 2 1 2 20 5 460 3 V 105 3 10 500 75 0 1 1 2 2 1 2 44 7 460 3 V 110 3 11 000 78 6 1 1 2 2 1 2 48 7 460 3 V 120 4 12 000 85 7 1 1 2 2 1 2 34 2 460 3 V 126 4 12 600 90 0 1 1 2 2 49 1 460 3 V 147 4 14 700 105 0 1 1 2 2 2 5 PSI 460 3 V 168 4 16 800 120 0 400 1 0 15 1 1 2 2 3 1 PSI 460 3 2 Motor ratings for only and gas oil burners using a direct drive pump 3 Remote oil pump is optional for frame size 1 and 2 but standard for frame sizes 3 and 4 All pump motors are 115 230 1 41 1 2 HP blower motor voltage is 115 230 1 5 Low High and Full Modulation minimum gas pressure 6 Lower gas supply pressure configurations available for New York City requirements Input is based on fuel BTU content listed furnace pressure and altitude of 2 000 feet or less If altitude gt 2 000 feet and lt 8 000 feet derate capacity 4 per 1 000 feet over 2 000 Consult factory for higher altitudes If furnace pressure exceeds listed value derate capacity 5 for every 0 5 w c of pressure in excess of stated Consult factory if derate exceeds 20 Gas input is based on natural gas with 1 000 BTU cu ft 0 60 gravity For total pressure at manifold add furnace pressure Oil input based on 140 000 BTU gal Consult factory for 50 Hz applications INDUSTRIAL COMBUSTION lt 30 PPM Low NOx Standard Specifications for LNVG LNVLG Series Gas Gas Oil Configuration Furnace Blower Remote Pressure Motor Oil Pump W C HP Motor HP Sta
17. At low fire the pressure range in the return line should be between 40 and 80 PSI with the oil metering valve position set between 6 and 8 on the scale At high fire the return line pressure will vary from 135 to 200 PSI dependent upon the brand of the oil nozzle At high fire the oil metering valve position will be approximately 2 on the scale 1 Set the MANUAL AUTO switch on the MANUAL position Position 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 the low fire position Adjust low fire with the metering valve position to have approximately 80 to 90 psi and adjust the low fire air shutter for a clean fire Record the combustion reading from the flue gas analyzer normally 4 5 to 6 5 O2 and less than No 1 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 the metering valve to close resulting in an increase in the oil pressure feeing the burner nozzle e At each point allow the burner to operate for a few minutes before recording the Oo CO smoke and pressure readings Observe that your and CO levels remain within an acceptable limit Adjust the oil pressure as necessary to correct th
18. Breaker Supplementary low overcurrent protection only No larger than 15 amps Auto Manual Modulation Auto position Selects boiler modulation control In this position the burner will Selector Switch operate automatically in response to load demand Manual position Selects 135 ohm potentiometer for manual modulating control Manual Modulating Control 135 ohm for full modulation burners only increases or decreases the burner firing rate manually Signal Lamps a POWER ON white illuminates when the control circuit is energized powered b IGNITION amber illuminates when the ignition transformer is powered and the pilot valve is energized opened c MAIN FUEL green illuminates when the main fuel valve or valves are energized open d FLAME FAILURE red illuminates when the flame safeguard system fails to detect pilot or main flame Warning Read the flame safeguard manual and fully understand its contents before attempting to operate this equipment Failure to do so may result in serious personal injury or death 1 2 IC SA 1511 02 2014 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION 1 3 2 Flame Safeguard Controls The flame safeguard controls the burner s operating sequence pre purge trial for ignition main flame and shutdown This safety control also includes flame detection system to confirm proper operation or cause a manual reset lockout in the event of a p
19. Fuel valves close Main fuel lamp goes off Flame safeguard timer starts Flame safeguard timer and burner motor stop Burner is ready for startup on the next call for heat 3 6 Manual Shutdown 1 2 Turn selector switch to the off position The burner shuts down in Automatic Shutdown as above When the burner motor stops close all manual valves 3 7 Safety Shutdown 1 If at any time during the operating cycle a flame failure occurs the burner shuts down as in Automatic Shutdown with an additional post purge and the flame failure lamp is energized The lockout switch on the flame safeguard control must be manually reset before the burner will fire again If a low water condition occurs the burner shuts down as in Automatic Shutdown If a high or low gas pressure condition occurs while firing on gas the burner shuts down as in Automatic Shutdown Condition must be corrected and the respective gas pressure switch manually reset before the burner will fire again on gas A Warning Read the flame safeguard manual and fully understand its contents before attempting to operate this equipment If the manual is not read and understood serious personal injury or death may result IC SA 1511 02 2014 3 5 V LNV Series Manual Operation INDUSTRIAL COMBUSTION Warning Should a starting failure occur for any reason combustible fumes may fill the combustion chamber Never attempt to re light the
20. MINIMUM OIL RETURN OIL RETURN CHECK BURNER BURNER NOZZLE CHECK Fp NOZZLE CHECK VALVE 5 D VALVE iex 4 p VALVE Il Il PRESSURE I PRESSURE I GAUGE GAUGE cate ati H ati H sz VALVE d VALVE i 9 3 is Mi Mi B et i NE AS A INET Wen amp INLET OIL METERING Up METERING FUEL VALVE FUEL VALVE STRAINER UNIT STRAINER UNIT VACUUM GAUGE W ISOLATOR VACUUM GAUGE W ISOLATOR GITE VF VALVE Eee Vave JAEYE TRANSFER TRANSFER PUMP 82 010157000 DUPLEX PUMP SYSTEM FIGURE 2 10 Typical Flooded Loop System 2 8 Gas Piping Refer to Figures 1 9 through 1 12 for typical gas piping arrangements Normally the control train is ordered to suit a particular code or insurance regulation such as UL cUL FM or GAP 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 IC SA 1511 02 2014 2 11 V LNV Series Manual Installation INDUSTRIAL COMBUSTION All piping must be in strict accordance with applicable codes ordinances and regulations of the supplying utility In the absence of other codes piping should be in accordance with the following standards National Fuel Gas Code NFPA No 54 ANSI No 2223 1 Gas train components upstream of the butterfly valve are shipped loose These components should be
21. Series Manual LNV Series FGR System INDUSTRIAL COMBUSTION MODULATING MOTOR FGR CONTROL VALVE 656 10219 000 FIGURE 7 5 FGR Control Valve High Fire Position 7 5 Air FGR Damper Assembly The Air FGR damper regulates the volume of combustion air Position of the rotary damper blade is controlled by a modutrol motor The damper blade in the low fire position is normally approximately 1 open at low fire The Air FGR damper and FGR control valve blades open as the modutrol motor drives toward the high fire position where flue gas is pulled into the regulated combustion air flow above the damper blade as controlled by the FGR control valve Combustion air mixed with flue gas is passed on through the blast tube to the combustion zone 7 6 Stack Temperature Interlock An optional stack temperature interlock device monitors flue gas temperature in the stack The stack temperature interlock is used as a low fire hold device The stack temperature interlock is set at 25 F below the minimum stack temperature at low fire nominal 200 F After the stack temperature rises above the set point the interlock closes and allows the burner to modulate 7 7 Blast Tube Temperature Interlock An optional blast tube temperature interlock device monitors air temperature in the blast tube area of the burner If the blast tube temperature rises above 200 F maximum An external scanner is used on the low emission burners
22. The supplying utility can provide this information as well as pressure correction factors To determine the required number of cubic feet per hour of gas divide burner input Btu hr by the heating value Btu cu ft NOTE When checking the input rate Make sure no other equipment is operating on the same meter 4 5 3 Main Gas Pressure Regulator The gas pressure required at the burner manifold is the pressure that is required to fire the burner at its rated capacity The gas pressure regulator must be adjusted to achieve this pressure to assure full input Refer to manufacturer s literature for regulator adjustment 4 5 4 Low Gas Pressure Switch Turn adjusting screw until indicator moves to a pressure setting slightly below the operating gas pressure The control will break a circuit if pressure is below this set point The control should be finally adjusted to prevent operation with low gas pressure but not at a pressure so close to normal operating pressure that unnecessary shutdowns occur The switch must be manually reset after tripping To reset allow gas pressure to rise and press the manual reset button IC SA 1511 02 2014 4 13 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 5 5 High Gas Pressure Switch Turn the adjusting screw until the indicator moves to a pressure setting slightly above the maximum operating gas pressure The control will break a circuit if pressure exceeds this value
23. airbox cover and loosening the two setscrews on the flex coupling 5 13 Gas System Z Caution All power must be disconnected before servicing the valves Check the gas train for leaks Check the gas valves and verify the low and high gas pressure settings IC SA 1511 02 2014 5 5 V LNV Series Manual Maintenance INDUSTRIAL COMBUSTION 5 13 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 bulletin for the correct procedure in coil replacement Should it become necessary to replace the complete valve be sure that the flow is in the direction of the arrow on the valve body Test for gas leaks and check valve action several times to ensure proper operation before attempting to relight the burner 5 13 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 shutoff to determine that it opens and closes If the va
24. 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 during the pre purge or firing cycle will cause a safety shutdown This type of shutdown requires manual reset of the programming control and must be corrected before operation can be resumed 3 10 IC SA 1511 02 2014 V LNV 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 require further adjustment after installation to assure maximum operating efficiency Prior to placing the boiler into initial service a complete inspection should be made of all controls connecting piping wiring and all fastenings such as nuts bolts and setscrews to be sure that no damage or misadjustments occurred during shipping and installation A combustion efficiency analysis made during the initial start up will help to determine what additional adjustments are required in a particular installation 4 2 Combustion Adjustment on Gas and Oil Efficient combustion cannot be properly judged by flame appearance although it may help in making preliminary settings The proper settings of air
25. burner under these conditions The combustion chamber must first be purged before re lighting Warning Keep fingers away from the combustion air intake below the damper The damper is actuated with sufficient force to cause severe injury Always make high and intermediate rate adjustments when the burner has reached low fire position Do not disturb the low fire setting 3 8 Startup and Operating 3 8 1 Gas Burners A gas valve leak test Bubble Test must be performed on the automatic safety shutoff valves located in the main gas train prior to any initial commissioning or subsequent maintenance of the burner and gas train systems where automatic valve proving systems interlocked with the main burner safety control are not provided This test should be performed periodically to ensure no leakage of valves in their closed or de energized position refer to valve manufacturers procedures The unit should be taken out of service if the unit fails any part of the gas valve leak test Any defective part must be replaced prior to putting the equipment back into service Warning Failure to follow this startup procedure may result in explosion fire property damage and personal injury This procedure must be performed only by authorized and qualified personnel Close the main and pilot gas cocks Make sure the ON OFF switch is in the OFF position and the fuel selector switch is tur
26. close to the stack as possible A modutrol motor with a 90 stroke opens and closes the FGR shutoff valve in 15 seconds Proof of closure for the shutoff valve is provided by an auxiliary switch in the modutrol motor The modutrol motor has a maximum temperature rating of 150 F This valve should never be mounted with the motor shaft in a vertical position Damage to the modutrol motor will result During pre purge and post purge the FGR shutoff valve is closed to prevent any unused gas fumes from returning to the combustion zone 1 MODUTRON MOTOR 2 F G R SHUTOFF VALVE 3 COUPLER ASSEMBLY 656 10219 000 FIGURE 7 3 FGR Shutoff Valve 7 4 FGR Control Valve Before starting the boiler make sure the control valve is closed The boiler must never be operated if the control valve is open This will result in hot combustion gases flowing backwards in the system This will damage the system and can cause bodily harm The FGR control valve is mounted to the FGR damper on the burner A burner mounted actuator with linkage connections coordinates the air fuel and NO control devices to provide proper fuel air NO ratios through the firing range The actuator must be able to complete its full travel range Restrictions will damage the motor and or the linkage The actuator transmits motion directly to the FGR control valve IC SA 1511 02 2014 7 3 V LNV Series Manual LNV Series FGR System INDUSTRIAL COMBUSTION 7 4 1
27. diffuser to the air baffle and compare it to the drawer assembly drawings in section 4 4 5 for firetube applications and 4 4 6 for watertube or cast iron applications 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 obtained Tighten the burner pipe locking setscrew securely IC SA 1511 02 2014 4 5 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 4 5 Drawer Assemblies for Firetube Boiler Applications 26 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 3 Drawer Assembly for VG Gas Only V13 34 Firetube 5 32 BETWEEN INNER EDGES OF ELECTRODE WIRES 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 7 16 FROM CENTER OF OIL NOZZLE TIP TO BOTTOM EDGE OF ELECTRODE WIRES 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 26 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 4 Drawer Assembly for VL Oil Only V13 34 Firetube 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 26 REAR FACE OF DIFFUSER TO E FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 5 Drawer Assembly for VLG Gas Oil V13 34 Firetu
28. down the burner for an extended period of time the operator should use the following general guidelines to protect the burner from its surrounding elements This will add to the operating life of the burner 1 2 3 Turn the main electrical disconnect switch to the burner to OFF Close all main fuel valves If the burner operates in a damp environment cover it with plastic to protect all electrical components from moisture Remove the burner control and store in a dry area IC SA 1511 02 2014 5 7 V LNV Series Manual Maintenance INDUSTRIAL COMBUSTION 5 17 Maintenance Flow Chart Recommended Test Schedule Item Service By Remarks DAILY Gauges Monitors Indica Operator Make Visual Inspection and record readings in log tors Instrument and Equipment Operator Make visual check against recommended specifications Settings Low Water Fuel Cutoff and Operator Refer to instructions Alarms WEEKLY Firing Rate Control Operator Verify factory settings Igniter Operator Make visual inspection Check flame signal strength Pilot and 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 Strengt
29. existing flow of combustion air as established initially for oil NOTE Do not readjust the air shutter when turning the combination burner for combustion of natural gas NOTE For burners equipped with a Siemens modulation motor fuel air adjustments for each fuel are independent of each other Refer to the Siemens modulating motor product literature for proper adjustment IC SA 1511 02 2014 4 19 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 7 1 On Off Combination Gas Oil Burner Adjustment 1 Turn the fuel selector switch to the OIL position 2 Turn the burner switch to the position 3 Proceed with startup and adjustments using the same procedures as explained in Section 4 5 1 4 After the system has been completely adjusted for oil firing place the burner switch to OFF and position the fuel selector switch to GAS 5 Proceed with startup and adjustments using the same procedures as explained in Section 4 4 10 Do not alter the air settings set for oil 4 7 2 Low High Off Low Combination Gas Oil Burner Adjustment 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 as explained in Section 4 5 2 4 After the system has been completely adjusted for oil firing place the burner switch to OFF and position the fuel selector sw
30. manifold is metered based on the butterfly valve low fire setting Pressure Atomization Two solenoid safety shut off valves initiate the flow of oil from the high pressure pump to a return flow nozzle In the return line from the nozzle an adjustable oil metering valve limits the amount of oil allowed to return to the pump The metering valve is connected to the damper actuator with mechanical linkage SAFETY 5 S SHUT OFF VALVES K e OIL RETURN OIL INLET NOZZLE q FLOW RATE METERING VALVE FULL MODULATION WITH RETURN FLOW NOZZLE The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s pressure setting less the volume of oil returning through the metering valve Damper is driven by the modulating actuator to a firing rate position determined by the modulating control or manual potentiometer Actuator can complete full travel to high fire in 30 sec Actuator will then continue to adjust firing rate position based on signals from the modulating control until RUN MODULATE Operating Sequence The gas valves remain in open position As the actuator begins it s travel to the firing rate position it adjusts the butterfl
31. of air must be reviewed as follows fom Feet per Minute cfm Cubic Feet per Minute Two 2 permanent air supply openings in the outer walls of the boiler room are recommended Locate one 1 at each end of the boiler room preferably 7 foot or lower This allows air to sweep the length of the boiler A boiler room vent fan is not recommended Under certain conditions these fans can cause a light vacuum and steal combustion air from the burner resulting in Size area and location unsatisfactory combustion performance of air supply openings in boiler room A vent fan in the boiler room is not recommended as it could create a light vacuum under certain conditions and cause variations in the volume of combustion air This can result in unsatisfactory burner performance Under no condition should the total area of the air supply openings be less than 1 square foot Size the openings by using the formula Area sq ft cfm fpm Combustion Air Rated bhp x 8 cfm bhp Amount of air required Ventilation Air Maximum bhp x 2 cfm bhp cfm Total recommended air 10 cfm bhp up to 1000 feet elevation Add 3 more per 1000 feet of added elevation Acceptable air velocity in From floor to 7 foot height 250 Boiler Room fpm Above 7 foot height 500 fpm Example Determine the area of the boiler room air supply openings for one 1 300 hp boiler at 800 feet altitude The
32. oil circulation at all times to avoid damage to and seizure of the pump 3 8 IC SA 1511 02 2014 V LNV Series Manual Operation INDUSTRIAL COMBUSTION BLOWER MOTOR ACCESS COVER IMPELLER WHEEL FLEXIBLE COUPLING FIGURE 3 1 Blower Motor and Flexible Coupling 656 10212 000 3 8 4 Fuel Chart Comparison for O Excess Air Oo Excess Air CO Natural Propane No 2 Oil 0 5 2 2 11 4 13 3 14 9 1 0 4 5 11 2 13 0 14 5 1 5 6 9 10 8 12 6 14 2 2 0 9 5 10 5 12 4 13 7 2 5 12 1 10 3 12 0 13 5 3 0 15 0 10 0 11 7 13 0 5 0 28 1 8 8 10 4 11 6 ne 5 5 31 9 8 5 10 0 113 iude Range 6 0 35 9 8 3 9 8 10 9 6 5 40 3 8 0 9 5 10 6 7 0 44 9 7 7 9 2 10 2 Low Fire Range 8 0 55 6 7 5 8 5 9 1 9 0 67 8 6 9 7 8 8 6 10 0 82 2 6 4 7 2 7 6 11 0 99 3 5 8 6 5 7 0 12 0 121 0 5 2 5 8 6 2 IC SA 1511 02 2014 V LNV Series Manual Operation INDUSTRIAL COMBUSTION Oo Excess Air Natural Gas Propane No 2 Oil NOTE Carbon Monoxide CO PPM should be attainable at levels below 50 PPM on most gun style burners regardless of the fuel being used In some instances this is not possible due to variables specific to a particular application ie furnace dimensions vessel construction etc Most codes limit the maximum CO to lt 400 PPM 3 9 Normal Operation Normal operati
33. pilot sequences to determine that the main gas valve opens Turn the burner switch OFF and let the programmer finish its cycle Check to see that the gas valve closes tightly 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 3 2 IC SA 1511 02 2014 V LNV Series Manual Operation INDUSTRIAL COMBUSTION When the conditions covered above and in Chapter 2 are assured the burner is ready for firing 3 1 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 position Refer to Chapter 4 for instructions 3 1 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 effic
34. returned to the low fire position before ignition is initiated From its closed position the damper is driven open by the flame safeguard control where it remains for the duration of the pre purge cycle Damper returns to the low fire position which is proven through the external switch The burner is now ready for startup Damper is driven open in 30 seconds by the two position actuator Low High Off burners have no provision to modulate the burner once high fire rate has been achieved Damper returns to its start position based on the 25 second closure speed of the mechanical actuator None Gas Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an in rush of gas A butterfly type gas metering valve is linked directly to the damper actuator and provides gas flow metering during the drive to the high position A manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valve s low fire setting The gas valves remain in their open position The actuator begins it s travel to the high fire position opening the gas metering valve The burner will remain at high fire until demand is satisfied On shut down all gas valves close within 1 sec
35. separate motor Oil Nozzle Pump pressurized oil discharges from the nozzle in a fine conical spray pattern The burner s nozzle is sized to provide the burner s high fire rate rated gallons per hour gph Smaller gph nozzles may be used to match burner output to a heat exchanger s required input Models V13 34 are supplied with simplex nozzles return flow nozzles optional on V25 34 Models V35 168 are supplied with return flow nozzles Nozzle Adapter A nozzle adaptor provides the means for connecting fuel lines with the nozzle Oil Solenoid Valves Two normally closed N C and one normally open N O solenoid valves are part of the oil system on LHO and LHL burners The two 2 N C valves provide positive shutoff of fuel oil while the one N O valve cycles the burner to high fire when closed 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 Oil Filter The oil filter prevents foreign matter from entering the burner oil system This item is provided as an option and shipped loose with the burner FUEL UNIT PRESSURE TAP OIL SUPPLY OIL RETURN TO TANK N C OIL VALVES 656 10211 000 FIGURE 1 3 On Off Oil System with Integral Pump amp Simplex Nozzle V13 25 1 6 IC SA 1511 02 2014 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION N C OIL VALVES OIL PRESSURE REG
36. this equipment 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 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 providing time for upkeep and maintenance Unusual noise improper gauge reading leak sign of overheating etc can indicate a developing malfunction requiring corrective action 5 2 Control System Most operating controls require very little maintenance beyond regular inspection Examine electrical connections Keep the controls clean Remove any dust from the interior of the control Covers should be left on controls at all times Keep the control cabinet doors closed Dust and dirt can damage motor starters and relay contacts Starter contacts are plated with silver and are not harmed by discoloration Never use files or abrasive materials such as sandpaper on contact points IC SA 1511 02 2014 5 1 V LNV Series Manual Maintenance INDUSTRIAL COMBUSTION A Warning When replacing a control or cleaning contacts be sure to disconnect the main power supply since the control is energized even though the burner switch is OFF More than one disconnect switch may be required
37. 0 4 7 3 Full Modulation Combination Gas Oil Burner Adjustment 4 20 4 8 Modulation Control 4 20 4 8 1 Linkage Control Adjustment 4 20 4 8 2 Cam Trim Adjustment 4 21 4 8 3 Parallel Positioning Adjustment 4 21 4 9 Air and Fuel Controls 4 22 4 9 1 Air Flow Control 4 22 4 9 2 Fuel and Air Flow Settings 4 23 CHAPTER 5 Maintenance 5 1 5 1 Overview 5 1 5 2 Control System 5 1 5 2 1 Programming Control 5 2 5 3 Air Handling System 5 2 5 4 Impeller and Inlet Cone 5 3 5 5 Firing Head Inspection 5 3 5 5 1 Drawer Assembly 5 3 5 6 Pilot and Ignition Electrode 5 3 5 7 Flame Scanner 5 4 5 8 Nozzle 5 4 iv IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 6 CHAPTER 7 5 9 Diffuser 5 5 5 10 Firing Rate Controls 5 5 5 11 Burner Mounting Inspection 5 5 5 12 Oil System 5 5 5 13 Gas System 5 5 5 13 1 Solenoid Valves 5 6 5 13 2 Motorized Main Gas Valves 5 6 5 14 Electrical System 5 6 5 14 1 Electric Motors 5 6 5 15 Checking Flame Failure 5 6 5 15 1 Pilot Flame Failure 5 6 5 15 2 Failure to Light Main Flame 5 7 5 15 3 Loss of Flame 5 7 5 16 Extended Shutdown 5 7 5 17 Maintenance Flow Chart Recommended Test Schedule 5 8 Troubleshooting 6 1 6 1 Awareness 6 1 6 2 Emergency Shutdown 6 2 6 3 Troubleshooting 6 3 LNV Series FGR System 7 1 7 1 Descriptio
38. 2 2 Smoke Measurement 4 2 4 2 3 Test Equipment 4 2 4 2 4 Gas Adjustments 4 2 4 2 5 Fuel Oil Adjustments 4 2 4 3 Electrical Interference Test 4 2 4 3 1 Gas Fired 4 2 4 3 2 Oil Fired 4 3 4 4 Burner Ignition Adjustment 4 3 4 4 1 Gas Pilot Flame Adjustment 4 3 4 4 2 Gas Pilot Turndown Test 4 3 4 4 3 Direct Spark Oil Only VL Adjustment V13 55 4 4 4 4 4 Burner Pilot Settings 4 4 4 4 5 Drawer Assemblies for Firetube Boiler Applications 4 6 4 4 6 Drawer Assemblies for Watertube Cast Iron Boiler Applications 4 9 4 5 Gas System 4 13 4 5 1 Gas Pressure 4 13 4 5 2 Gas Flow 4 13 4 5 3 Main Gas Pressure Regulator 4 13 4 5 4 Low Gas Pressure Switch 4 13 4 5 5 High Gas Pressure Switch 4 14 4 5 6 Gas Combustion Adjustment 4 14 4 5 7 On Off Gas Burner Adjustment 4 14 4 5 8 Low High Off Low Gas Burner Adjustment 4 15 IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION 4 5 9 Full Modulation Gas Burner Adjustment 4 16 4 5 10 Low NOx Full Modulation Combination Gas Burner Adjustment 4 16 4 6 OilSystem 4 17 4 6 1 On Off Oil Burner Adjustment 4 18 4 6 2 Low High Off Low Oil Burner Adjustment 4 18 4 6 3 Full Modulation Oil Burner Adjustment 4 18 4 7 Combination Gas Oil System 4 19 4 7 1 On Off Combination Gas Oil Burner Adjustment 4 20 4 7 2 Low High Off Low Combination Gas Oil Burner Adjustment 4 2
39. 2 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION 2 7 5 Two Pipe Multiple Burner System Several options exist for a multiple burner installation Figure 2 7 is a typical installation showing separate suction lines for each burner with a common return line Figure 2 8 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 9 shows an installation using a day tank A pump supplies oil to the day tank Figure 2 10 shows a flooded loop system The circulating pump is sized according to the maximum burner firing rate for all burner plus a 30 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 OIL RETURN BURNER NOZZLE FUEL VALVE FILTER UNIT 627 01011 000 altered for single burner FIGURE 2 6 Typical No 2 Oil Loop Single Burner IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION Installation RETURN TO TANK OIL RETURN GATE
40. 7 3 8 7 3 8 7 3 8 Diameter H 12 7 8 15 16 3 4 17 1 2 Bolt circle diameter 11 1 4 13 1 4 15 1 4 15 3 8 Center line to main gas inlet L 9 5 8 9 5 8 10 1 2 11 Mounting flange to main gas inlet E 6 7 8 7 1 4 7 5 8 9 1 2 INDUSTRIAL COMBUSTION V Series Standard Dimensions lt 30 PPM Low NOx Configuration Accompanying dimensions are for layout purposes only Burner Frame Size amp Model Number DIM Size 1 Size 2 Size 3 Size 4 Overall length A 37 1 4 40 3 8 45 1 4 51 1 8 Center line to right side standard M 14 13 5 8 16 7 8 21 7 8 Center line to left side standard N 12 7 16 13 7 8 14 5 8 17 Center line to right side inverted N 12 7 16 13 7 8 14 5 8 17 Center line to left side inverted S 14 13 5 8 16 7 8 21 7 8 Center line to top standard J 9 1 2 9 1 8 8 3 8 9 3 4 Center line to bottom standard K 11 3 4 14 7 16 18 5 8 19 1 4 Center line to burner support standard P 11 3 4 14 7 16 18 5 8 19 1 4 Center line to top inverted R 28 30 5 8 34 3 4 35 1 2 Center line to CL of main gas inlet inverted Q 6 7 8 8 Extension standard C 4 4 4 5 Extension maximum C 5 5 5 6 Diameter D 8 1 4 10 11 1 2 13 5 8 Panel box depth G 7 3 8 7 3 8 7 3 8 7 3 8 Diameter H 12 7 8 15 16 3 4 17 1 2 Bolt circle diameter 11 1 4 13 1 4 15 1 4 15 3 8 Center line to main gas inlet L 9 5 8 9 5 8 10 1 2 11 Mounting flange to main gas
41. 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 6 Make certain that the operator in charge is properly instructed in operation and maintenance procedures ACaution Before opening the manual gas shutoff valves read the regulator instructions carefully The instructions are in the regulator box Follow the manufacturer s 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 valve quickly will damage the regulator Do not exceed the regulator pressure ratings 2 12 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION 2 10 Firing Modes ON OFF OPERATION Combustion Air Gas Oil COMPONENTS DESCRIPTION Fixed two bladed damper Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve On diaphragm gas valve the time to open can be adjusted by a bleed valve On models with motorized valves the time to open is fixed at 13 seconds A manually adjusted gas regulator limits firing rate Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle Oil flow
42. DESCRIPTION OF THE EQUIPMENT THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE CONTAINED HEREIN TO THE EXTENT PERMITTED BY THE LAW THERE ARE NO IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE THE PROVISIONS AS TO DURATION WARRANTY ADJUSTMENT AND LIMITATION OF LIABILITY SHALL BE THE SAME FOR BOTH IMPLIED WARRANTIES IF ANY AND EXPRESSED WARRANTIES I 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 or replace BUT NOT INSTALL F 0 B Company s plant any part or parts of the equipment which within twelve 12 months from the date of initial operation but no more than eighteen 18 months from date of shipment shall prove the Company s satisfaction including return to the Company s plant transportation prepaid for inspection if required by the Company to be defective within the above warrant
43. GURE 1 10 Typical Gas Train for LHO System V13 34 IC SA 1511 02 2014 1 11 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION BUTTERFLY TO BURNER VALVE MER E 7 RI SHUTOFF le COCK 7 INPUT FROM SUPPLY 571 0014 FIGURE 1 11 Typical Gas Train for Full Modulation System V13 34 HIGH GAS PRESSURE SWITCH OUTPUT TO BURNER LOW GAS PRESSURE SWITCH SHUTOFF COCK COCK 7 INPUT FROM SUPPLY 571 0015 FIGURE 1 12 Typical Gas Train for LHO LHL Systems V35 63 amp Full Modulation Systems V35 168 1 12 IC SA 1511 02 2014 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION 1 7 2 Pilot Gas Train Components Models VL 60 168 as well as all VG and VLG models are supplied with a gas pilot system Oil only models VL 13 55 are supplied with direct spark ignition Component Description Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to the pilot It closes after main flame is established Gas Pressure Regulator Reduces gas pressure to that required by the pilot Gas Pilot Shutoff Cock For manually closing the pilot gas supply PILOT SHUTOFF TO GAS PILOT COCK 11 REGULATOR PILOT VALVE GAS 656 09864 FLOW FIGURE 1 13 Pilot Gas Train ELECTRODE END TIP TO TUBE WITHIN 1 00 GAP OF
44. STION Installation 2 4 Combustion Chamber Recommendations 2 4 1 Combustion Chamber Drawings Firetube Boiler Application lt S 2 SX S um 2 lt S eS lt gt gt 5 o Q o S a Ses TER S K 252 2 4 LA Ld SH SEK Q LXX KX 2 SEK XR 55 SR S x 55 LS X 5S lt 1 S xX rox ox xX lt gt e 555 RRR KX xx EXEL FIGURE 2 2 Inverted Configuration for Firetube Boiler 2 2 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION 2 4 2 Combustion Chamber Dimensions Inverted and Standard Configuration Firetube Boiler Combustion Burner Chamber Model A B C D E Min Length 13 6 28 6 11 37 56 15 6 28 7 11 37 56 17 6 28 7 11 37 56 20 6 28 8 11 37 56 21 6 28 8 11 37 56 25 6 28 8 11 37 56 30 6 28 9 11 37 56 34 6 28 10 11 37 56 35 6 31 10 14 40 62 40 6 31 11 14 40 62 42 6 31 11 14 40 62 45 6 31 12 14 40 62 50 6 31 12 14 40 62 54 6 31 13 14 40 62 55 6 31 13 14 40 62 60 6 36 13 18 46 83 63 6 36 14 18 46 83 70 6 36 14 18 46 83 80 6 36 16 18 46 83 84 6 36 16 18 46 83 90 6 36 16 18 46 83
45. Standards Fuel Pressure Atomization VG Gas VL 2 Oil VLG 2 Oil and Gas LNVG Gas LNVLG 2 Oil and Gas Model Example The model number on the nameplate is VLG 45 No 2 oil and gas burner with input rated at 4 500 MBtu hr against furnace pressures up to 2 0 W C at 60hz NOTE Firing at higher furnace pressures de rates the burner by approximately 5 per 1 2 inch of additional pressure Consult with the factory Burner linkages cams fuel metering valves and positioning motors have not been pre set by the factory for proper combustion and must be set by a qualified and authorized technician Failure to follow this procedure could result in property damage and personal injury The installation of a burner shall be in accordance with the regulations of authorities having jurisdiction The equipment must be installed in accordance with applicable local state or provincial installation requirements including the National Electrical Code NEC and Associated Insurance Underwriters Where applicable the Canadian Gas Association CGA B149 and Canadian Standard Association CSA B140 and B139 for oil burners codes shall prevail Oil and gas burning equipment shall be connected to flues having sufficient draft at all times to assure safe and proper operation of the burner The V series burners are designed to burn either gas or light oil No 1 or 2 as defined by ASTM D396 2010 specifications Do not use gasoline c
46. The programming control sequences the operation of all controls and components through the starting ignition firing and shutdown cycle The burner and control system are in starting condition when The operating and high limit control temperature or pressure are below their cutoff setting All power supply switches are closed Power is present at the control panel Refer to the manufacturer s literature on programming controls and burner wiring diagram for detailed information 1 Begin starting sequence with burner switch off and with all manual valves closed Switch main power on 3 4 IC SA 1511 02 2014 V LNV Series Manual Operation INDUSTRIAL COMBUSTION 9m gt Y 9 When firing oil open the manual oil valves When firing on gas open the main manual gas valve When firing on gas manually reset the high and low gas pressure switches if applicable Place the gas oil selector switch if applicable in position for the desired fuel With all limit and operating controls calling for heat the burner will follow the flame safeguard sequence When the burner motor starts open the gas cock If firing on gas when the main fuel lamp lights indicating pilot flame proven slowly open the second shutoff cock downstream of the main gas valve s Refer to the manufacturer s literature on primary control sequence of operations 3 5 Automatic Shutdown Limit or operating controls open 1 2
47. ULATOR N O OIL RETURN OIL VALVE TO TANK 656 10211 000 FIGURE 1 4 LHL Oil System with Integral Pump amp Simplex Nozzle V13 34 N C OIL OIL VALVES NOZZLE OIL PRESSURE REGULATOR N O OIL RETURN TO TANK OILVALVE 656 10211 000 FIGURE 1 5 LHL Oil System with Integral Pump amp Return Flow Nozzle V13 55 IC SA 1511 02 2014 1 7 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION MODULATING MOTOR SWITCH OIL NOZZLE FUEL UNIT PRESSURE TAP OIL RETURN TO TANK 656 10211 000 NODULATING MOTOR FUEL UNIT PRESSURE TAP OIL NOZZLE FUEL UNIT PRESSURE TAP FUEL UNIT OIL RETURN TO TANK 656 10211 000 FIGURE 1 7 Full Modulation Oil System with Integral Pump amp Return Flow Nozzle V13 55 1 8 IC SA 1511 02 2014 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION MODULATING OIL SUPPLY TO NOZZLE 5 Lr AL du 1 FUEL UNIT ea pr PRESSURE TAP OX ag 3L ar qu dy OIL RETURN gt j OIL N C 10211 METERING UM 656 10211 000 REMOTE FUEL AIVE UNIT FIGURE 1 8 Full Modulation Oil System with a Remote Pump V60 168 1 6 2 Operation Fuel oil is delivered to the fuel pump either by gravity fuel pump suction or by a circulating pump through a fuel oil filter Pressurized fuel returns to the storage tank until the two solenoid valves ope
48. USTION spring hold the valve closed On call for heat the controller contacts close and the coil is energized This pulls the plunger to the UP position opening the bleed port and closing the supply port The gas in the top of the valve flows out through the bleed port This reduces the pressure on top of the diaphragm allowing the gas pressure below to lift the diaphragm and open the valve 5 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 3 0 to 4 0 O with a target value of less than 50 ppm CO 6 After completing all adjustments replace the regulator gaskets and slotted aluminum screw cap Tighten all linkages and marked settings The burner should be adjusted to provide correct fuel flow at a constant rate as indicated on the burner data plate Complete the Startup Report 4 5 8 Low High Off Low Gas Burner Adjustment The gas burner adjustments on a Low High Off system consist of the gas pressure regulator gas butterfly valve low and high gas pressure switches and an air damper assembly The auxiliary switch inside the M436 Mod motor makes or breaks the high fire gas See Figure XYZ for switch adjustment 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 s
49. V LNV SERIES Installation Operation and Service Manual INDUSTRIAL COMBUSTION amp WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SER VICE THIS EQUIPMENT IC SA 1511 02 2014 INDUSTRIAL COMBUSTION V LNV SERIES Installation Operation and Service Manual 656 10219 000 Manual Number IC SA 1511 Release Date September 2010 INDUSTRIAL COMBUSTION Copyright 2014 by Industrial Combustion All rights reserved No part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means without the prior written consent of Industrial Combustion Industrial Combustion 351 21st Street Monroe WI 53566 608 325 3141 ind comb com INDUSTRIAL COMBUSTION PREFACE Warning 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 to others Z 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 Model
50. VALVE BURNER NOZZLE OIL INLET METERING VALVE FILTER 627 01011 000 FIGURE 2 7 Multiple Burners with Separate Suction Lines RETURN TO TANK LA My CHECK mh VALVE SUPPLY TO BURNERS CHECK E S VALVE BURNER SE 45 x NOZZLE 9 82 m PRESSURE GAUGE I T W ISOLATOR GAUGES OIL RETURN W ISOLATORS i CATE fed gt gt VALVE VOLUME QA i CONTROL BY PASS Oaah 1 Qi m OIL INLET OIL METERING p FUEL VALVE FILTER FILTER VACUUM OR COMPOUND GAUGE W ISOLATOR 2 GATE VALVE CHECK STRAINER JSt 627 01012 000 FIGURE 2 8 Typical Oil Loop for Multiple Burners with Transfer Pump FILTER CHECK VALVE VALVE SUPPLY TO BURNERS GATE VALVE OIL RETURN BURNER NOZZLE OIL INLET oL METERING FUEL VALVE UNIT BACK PRESSURE VALVE SET BELOW 3 PSI BURNER NOZZLE o I OIL RETURN ahi E Pate te E od SE IVI D OIL INLET S OIL METERING FUEL VALVE UNIT RELIEF VALVE TRANSFER PUMP 2 10 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION OIL RETURN BURNER NOZZLE RELIEF VACUUM OR COMPOUND VALVE GAUGE W ISOLATOR GATE e VALVE CHECK METERING VALVE FU TRANSFER STRAINER UNIT PUMP STRAINER 627 01013 000 FIGURE 2 9 Typical Installation Using Day Tank 6
51. XTENSION 6 EXTENSION 8 EXTENSION 3 FIT BOILER SECTION A FIGURE 2 5 V Series Refractory Dimensions 2 6 Packing Plastic Insulation Around Oven If Dry Oven is Supplied The area between the outside circumference of the dry oven and existing refractory should be packed with Kaiser Refractory Mono T 9 Airset or equal within two hours after coating the dry oven with Trowleze From inside the furnace ram the plastic refractory from the front to the rear parallel to the outside surface of the dry oven N Caution It is important that you provide support for the housing when in the open position to prevent damage to the hinges and subsequent components IC SA 1511 02 2014 2 7 V LNV Series Manual Installation INDUSTRIAL COMBUSTION 2 7 Oil Piping 2 7 1 Pressure Atomization Oil Piping The oil only VL and gas oil VLG model burners use pressure atomization Fuel oil is provided by a burner mounted fuel pump directly coupled to the blower motor via a flexible coupling for models V13 55 A remote pump is used for models V60 168 The suction and return line sizes two pipe system are based on the suction rate of the fuel pump and not the burner firing rate Pipe size must be selected so that suction vacuum is within suitable limits 2 7 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
52. accompanying wiring diagram for information on adjusting the system In a properly tuned parallel positioning system the independent actuators for fuel air and FGR if so equipped will be coordinated to provide optimum combustion throughout the firing range 4 9 Air and Fuel Controls 4 9 1 Air Flow Control The V series burners have a two blade air shutter design Both blades are coupled together and are attached to the modulation motor Changing the positions of the linkage rods on the linkage control arms will change the way the damper blades open and close 4 22 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 9 2 Fuel and Air Flow Settings Fuel and air flow rates can be individually adjusted at low fire and high fire to achieve rated heat input firing rate turndown optimum efficiency safe operation and the ability to cope with environmental changes air temperature humidity barometric pressure and fuel property changes Adjustments may be required to meet certain environmental emissions criteria such as NOx or CO Combustion adjustments also vary with specific system applications Turndown capability for oil is less than that of natural gas On combination fueled burners gas turndown performance may be restricted by the excess air and fuel turndown levels set for oil combustion Excess air O2 and unburned fuel CO levels in boiler flue gases are used to determine combusti
53. air openings are to be 5 feet above floor level 1 Air required 300 x 10 3000 cfm 2 Air velocity Up to 7 feet 250 fpm 3 Area required Area cfm 3000 250 12 sq ft total 4 Area Opening 12 2 6 sq ft opening 2 required 1 4 IC SA 1511 02 2014 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION 1 5 Firing Head Two side access covers provide access to the firing head internal components The firing head configuration is dependent upon the heat exchanger it is attached to Figure 1 1 shows a a radial spud firing head typically used on watertube applications while Figure 1 2 illustrates a typical arrangement for firetube applications GAS MANIFOLD MOUNTING FLANGE AIR BAFFLE CHOKE RING NOZZLE BODY AND TIP RADIAL GAS SPUDS FIGURE 1 1 Burner Housing Watertube Applications r DIFFUSER MOUNTING FLANGE AIR BAFFLE GAS MANIFOLD CHOKE RING NOZZLE BODY AND TIP FIGURE 1 2 Burner Housing Firetube Applications IC SA 1511 02 2014 1 5 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION 1 6 Oil System The V series burners pump high pressure fuel oil to the spray nozzle resulting in combustion ready finely atomized oil spray 1 6 1 Oil System Components Fuel Unit Standard V13 55 have an oil pump flex coupled to the blower motor these units may be optionally equipped with a remote pump The larger V60 168 use a remote pump with
54. alve is in the nearly closed position 2 Start the burner and hold at low fire until the boiler is at the proper operating pressure or temperature 4 16 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 3 With an analyzer in the stack adjust the FGR valve cam screw to obtain lt 30 ppm NOx levels NOTE Do not adjust the burner below lt 20 ppm Unstable combustion and high CO emissions will result 4 Monitor and CO levels during this process The introduction of FGR into the combustion chamber will lower the flue Os levels Too much FGR may induce high levels of CO in the flue gas It may be necessary to adjust the air damper blades to raise the O to proper low fire values If the proper NOx values can not be reached by adjusting the cam screw the FGR linkage will have to be adjusted as well 5 Once the low fire setting is complete continue with the instructions above adjusting the cam at each screw to obtain the proper NOx values Verify the values modulating back to low fire and adjust accordingly 4 6 Oil System Refer to the burner data plate located inside the control panel door The nameplate will list the following burner information burner and control voltage phase e cycle motor amperage 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 firin
55. ammer 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 Check to make certain that all plugs connections linkages etc are tight The following checks must be made Component Check Boiler Check boiler water level Be sure all boiler valves are installed correctly and positioned properly Set the high limit control slightly above the operating control Set the operating control at the desired temperature or pressure Burner For protection in shipment the flame safeguard control chassis is shipped unmounted Check all screw connections before attaching the flame safeguard chassis to the base The screw must be secure to assure low resistance connections The relay chassis is mounted on the subbase with a screw which when tightened completes the connection between the subbase and chassis contacts Press the manual reset button to be sure safety switch contacts are closed e 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 e Check motor rotation by momentarily closing the starter or relay Blower rotation is clockwise when viewed fro
56. anifold pressure matches the rating on the burner data plate Verify and record the readings and pressures high fire is typically 396 to 4 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 2096 below and 2096 higher than normal pressure 8 Verify low fire and high fire rate by clicking the meter as previously explained 9 After completing all adjustments replace the regulators gaskets and slotted aluminum screw caps Tighten all linkages and marked settings The burner should be adjusted to provide correct fuel flow at a constant rate as indicated on the burner data plate Complete the Startup Report IC SA 1511 02 2014 4 15 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 5 9 Full Modulation Gas Burner Adjustment The burner adjustments on a full modulation gas burner consist of the gas pressure regulator butterfly gas valve low nad high gas pressure switches model V30 168 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 pressure that is required to
57. at the factory Wiring from the burner panel to boiler controls low water controls remote compressor motor and remotely located fuel valves is furnished by the installer 2 2 Draft Conditions A boiler or other heating vessel fired with a V series burner does not depend on chimney draft for proper combustion 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 connected 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 3 Combustion Air Supply The space in which a burner operates must be supplied with adequate fresh air for combustion and ventilation purposes Fresh air supply must meet or exceed all code requirements Consult with insurance carrier and or local authorities for specific regulations Warning 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 IC SA 1511 02 2014 2 1 V LNV Series Manual INDUSTRIAL COMBU
58. ated 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 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 assembly is clear of the burner head bracket turn the pilot assembly and retract it through the access hole 9 Inspect the electrode and adjust the gap if necessary 10 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 cable should not be exposed to moisture abrasion or rough handling 13 See that the connectors are in perfect contact with the cable end Unscrewing the snap portion of the connector will show whether this is true gt YS DN N 5 7 Scanner The scanner must be clean Even small amount of contamination will reduce the flame signal Wipe the scanner lens with a clean soft cloth Check pilot and flame signal strength To insure proper atomizing the tip must be screwed in tightly with the swirler seating spring pressing the swirler tight against the nozzle tip Turn the swir
59. be 4 6 IC SA 1511 02 2014 V LNV Series Manual Adjustments DUSTRIAL COMBUSTION 16 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4 6 Drawer Assembly for VG Gas Only V35 55 Firetube 7 16 FROM CENTER OF OIL NOZZLE TIP 5 32 BETWEEN TO BOTTOM EDGE INNER EDGES OF OF ELECTRODE WIRES ELECTRODE WIRES 25 NOZZLE TO OUTER EDGE OF ELECTRODE WIRES 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 26 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 7 Drawer Assembly for VL Oil Only V35 55 Firetube 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 16 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 8 Drawer Assembly for VLG Gas Oil V35 55 Firetube IC SA 1511 02 2014 4 7 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 16 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 9 Drawer Assembly for VG Gas Only V60 110 Firetube 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 16 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 10 Drawer Assembly for VLG Gas Oil V60 110 Firetube 15 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 11 Drawer Assembly for VG Gas Only V120 168 Firetube
60. blower will run through post purge and stop Turn the burner switch off and reset the safety switch Re open the gas pilot shutoff cock and re establish main fuel supply 5 6 IC SA 1511 02 2014 V LNV Series Manual 5 15 2 Failure to Light Main Flame INDUSTRIAL COMBUSTION 5 15 2 Failure to Light Main Flame 1 2 Shut off the main fuel supply and leave the gas pilot shutoff cock open Turn the switch on The pilot will light upon completion of the pre purge period The main fuel valves will be energized but there should be no main flame The fuel valves de energize within four seconds after the main burner ignition trial ends The control will lock out on a safety shutdown The flame failure light and optional alarm will be activated The blower motor will run through the post purge and stop Turn the burner switch off and reset the safety switch Re establish main fuel supply 5 15 3 Loss of Flame With the burner in normal operation shut off the main burner fuel supply to extinguish main flame The fuel valves will be de energized and the relay will signal the condition within four seconds The control will then lock out on a safety shutdown The flame failure light and optional alarm ill be activated The blower motor will run through the post purge period and stop Turn the burner switch off and reset the safety switch Re establish the main fuel supply 5 16 Extended Shutdown When shutting
61. cal shock Failure to follow these instructions could result in serious personal injury or death 6 1 Awareness Chapter 6 assumes that The unit in question has been properly installed and that it has been running for some time 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 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 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 downtime or delays can be prevented by systematic checks of actual operation against the normal IC SA 1511 02 2014 6 1 V LNV Series Manual Troubleshooting INDUSTRIAL COMBUSTION sequence to determine the stage at which performance deviates from normal By following a se
62. close The metering valve opens to it s low fire position in 30 seconds with the damper actuator The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supply system 2 20 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION FULL MODULATION OPEN DAMPER PURGE Combustion Air Gas On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut off valve Options are available for 4 20amp SAFETY SHUT OFF NOZZLE modulating signal conversion or 4 20 VALVES D proportional modulating actuators VARIATIONS Also optional is an actuator with dual low fire start switch positions for improved turndown in dual fuel X FLOW RATE situations METERING VALVE FULL MODULATION OIL RETURN WITH SIMPLEX NOZZLE OIL INLET IC SA 1511 02 2014 2 21 V LNV Series Manual INDUSTRIAL COMBUSTION Installation PARALLEL POSITIONING COMPONENTS DESCRIPTION PRE PURGE STARTUP IGNITION RUN MODULATE Operating Sequence SHUT DOWN VARIATIONS POST PURGE NOTE Parallel Positioning systems incorporate independent actuators to control each of the fuel and air metering devices Customizable curves can then be created for each actuator to
63. e blast tube with a scribed or pencil line where the three mounting screws are located to insure that the diffuser is placed back in the same position 3 Remove the screws holding the diffuser to the blast tube and slowly pull the diffuser along the blast tube towards the firing head 4 Clean all carbon from the diffuser vanes and reinstall in reverse order of disassembly aligning the diffuser with the scribed marks 5 When reinstalling be sure the diffuser is centered with the proper distance 5 10 Firing Rate Controls Check all rods and linkages Make sure all connections are tight Adjust if necessary Perform a combustion test as explained in Chapter 4 and readjust the burner if necessary 5 11 Burner Mounting Inspection The seal between the burner flange and furnace front plate must not permit combustion gases to escape Periodic inspection is important If leaking occurs refer to Chapter 2 for proper sealing procedures 5 12 Oil System Little maintenance is required on the oil systems other than cleaning the oil filter This procedure should be done at regular intervals Increased inlet vacuum reading may indicate a clogged filter Follow the strainer manufacturer 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 You access the coupling by removing the
64. eas between the burner flange and the boiler front plate to prevent leakage of combustion gases 2 5 Installation Prepare the boiler front plate as follows 1 Determine burner mounting height Locate and scribe a level horizontal centerline across the mounting face 2 Locate and scribe a 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 insulating rope gasket wrap the rope on the inside of the bolt circle looping the rope around the mounting studs 4 Set the burner into position for mounting and tighten into place Standard burners are equipped with a four hole mounting flange 5 Permanently support the burner using the pipe support connections 6 The space between the boiler refractory water leg or fire tube and outside diameter of the firing head 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 firing head 2 6 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL OMBUSTION BLAST TUBE INSERTION DEPTH 2 EXTENSION 4 E
65. ens the air damper and fuel metering valves increase the firing rate Optional CAM trim provides additional precision to the air fuel mix with the use of several discrete set point adjustments across the modulation range Further combustion efficiency may be achieved with the use of parallel positioning controls which use multiple directly coupled actuators linkeageless to position the air damper fuel metering valves and if applicable flue gas recirculation FGR across the modulation range 1 4 Combustion Air Handling System Component Description Motor and Blower The combustion air fan is driven by a 3450 rpm blower motor Air Volume Air dampers are located in the air inlet housing The dampers are mechanically linked and Regulator actuated by a two position motor or hydraulic cylinder for on off operation LHO LHL or full modulation burners have the dampers mechanically linked to the modulating motor Combustion Air A pressure sensitive differential switch actuated by air pressure created by the blower fan Proving Switch Contacts close to prove combustion air flow Diffuser Contained by the burner s firing head an air flow diffuser shapes combustion air flow and improves flame stability IC SA 1511 02 2014 1 3 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION 1 4 1 Boiler Room Combustion Air When determining boiler room air requirements the size of the room airflow and velocity
66. ent Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt 12 Set the gas low fire rate by adjusting the butterfly valve and air linkage 13 When low fire is adjusted shut down the burner 14 Restart several times to be sure the low fire setting is suitable Readjust if necessary Never start the burner with fuel vapor in the furnace In case of an emergency open the main power switches and close all fuel valves 15 After combustion adjustments are satisfactorily set allow the heating vessel to slowly reach normal operating pressure or temperature 16 Turn the potentiometer switch to the high fire position Check high fire at this point using combustion instruments 17 Do not disturb established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate settings 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 Set the gas low fire rate by adjusting the butterfly valve and air linkage Refer to the adjustment section of this manual Using the combustion analysis instrument adjust the low fire Typical combustion analysis for low fire is 5 to 6 on standard turndown systems and between 6 5 and 9 for higher turndown systems Verify the minimum input rate by measuring the gas meter When low fire is adjusted shut dow
67. eries Manual Adjustments INDUSTRIAL COMBUSTION 3 Upon completion of successful test proceed with startup procedures 4 3 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 Start the burner and at the time of pilot trial with just the electrical ignition system energized the flame relay should not pull in Upon completion of successful test disconnect the power supply 7 Reconnect the oil safety shutoff valve and turn on the manual pilot gas valve 8 Reconnect the power supply and proceed with startup procedures o amp BN 9 4 4 Burner Ignition Adjustment 4 4 1 Gas Pilot Flame Adjustment The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator Normal setting is 4 to 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame To adjust pilot gas pressure unscrew regulator cap and turn the adjusting screw in or out 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 maintenance test the pilot flame signal pilot turndown and safety switch lockout Refer to the flame safeguard in
68. es Manual Introduction INDUSTRIAL COMBUSTION valve Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating sequence 1 7 1 Main Gas Train Components 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 Main Gas Train Component Description Gas Volume Valve The butterfly type valve is positioned by linkage from the modulating motor and controls the gas flow rate Main Gas Valves Electrically operated safety shutoff valve s that open to admit gas to the burner low fire Standard UL burners include Models V13 25 diaphragm gas valve amp solenoid valve e Models V30 50 one 1 motorized gas valve w proof of closure or two 2 safety shutoff valves Models V55 120 one 1 motorized gas valve w proof of closure and one 1 safety shutoff valve Models V126 168 two 2 motorized gas valves two motorized gas valves can be optionally provided on all models Main Gas Regulator Regulates gas train pressure to specified pressure required at the burner manifold Input is set by main gas pressure regulator adjustment Main Gas Cocks Used for manual shutoff of the gas supply upstream of the pressure regulator A second shutoff cock downstream of the main gas valve s provides a means of testing for leakage through the gas valve s High Ga
69. es from the electrodes for direct spark applications Pull the drawer assembly completely out of the housing 5 To reinstall the drawer assembly insert it part way into the housing connect the ignition cables if applicable and seat the assembly fully Install the access cover bolts loosely Slide the cover into the original location and tighten the bolts Reconnect the fuel lines a N 5 6 Pilot and Ignition Electrode Failure to keep the ignition electrode clean and properly set can cause faulty 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 pilot and drawer assembly drawings in Chapter 4 IC SA 1511 02 2014 5 3 V LNV Series Manual Maintenance INDUSTRIAL COMBUSTION For burners equipped with a gas pilot the pilot is loc
70. f the Company to the Buyer for such parts than the Company s warranty adjustment covering part manufactured by the Company as set forth in this subparagraph 10 4 Expenses incurred by Buyer in replacing or repairing or returning the spare or replacement parts will not be reimbursed by the Company Limitation of Liability The above warranty adjustment set forth Buyer s exclusive remedy and the extent of the Company s liability for breach of implied if any and express warranties representations instructions or defects from any cause in connection with the sale or use of the 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 1511 02 2014 V LNV 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 Voltage Amperage Electric Motors L1 L2 L3 Control Voltage Blower Motor Air Compressor r NNNE
71. fire the burner at its rated capacity To adjust the regulator unscrew the cap located on the top and turn the adjustment screw clockwise to increase pressure or clockwise to decrease pressure Set the MANUAL AUTO switch to the MANUAL position Position 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 the low fire position After a few seconds the O analyzer should have an accurate reading of the O present in the flue gas Normally levels are set between 4 to 6 at low fire for standard turndown systems on gas and 6 to 996 O for high turndown systems with the target value of less than 50 ppm CO To obtain the proper readings 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 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 8 At each point allow the burner to operate for a few minutes before recording the CO and pressure readings Observe that the and CO levels remain within an acceptable limit Adjust the pressure regulator as necessary to correct this situation Continue to do this until the burner reaches high fire the potenti
72. fuel ratios must be determined by flue gas analysis Combustion gas analysis indicates the air to fuel ratio and the degree of complete combustion Instruments are available to measure carbon dioxide CO oxygen O and carbon monoxide CO At no time should CO measurements alone be used to indicate proper excess air levels Only Oo 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 Stack temperature should be as low as possible without causing flue gas condensation Stack heat loss can be reduced by decreasing either the temperature or the volume of the flue gas or both Flue gas temperature is reduced by improving heat transfer or by reducing excess combustion air A certain amount of excess air is necessary to complete combustion More efficient burners require minimum excess air IC SA 1511 02 2014 4 1 V LNV 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 equipment used and instructions accompanying the instrument should be followed Smoky combustion can result from Improper air delivery Insufficient draft e Improper fuel viscosity e Imp
73. g rate These procedures assume that the pre startup tasks and check list have been performed in accordance with the instructions in this manual For most efficient combustion allow the boiler to fully warm up before making adjustments Refer to the boiler instruction manual for the boiler control settings TYPICAL LOCATION OF THE POINTER WHEN AT HIGH FIRE FIGURE 4 23 Oil Metering Adjustment Knob IC SA 1511 02 2014 4 17 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 6 1 On Off Oil Burner Adjustment On Off burners use the Suntec B2TC 8931 oil pump model High fire pressure adjustment is 200 300 psi solenoid energized and low fire pressure adjustment is 100 200 psi solenoid de energized 1 Briefly push in the starter contact and release to ensure that the blower motor and oil pump are rotating in the correct direction 2 Turn the burner switch to the ON position 3 Make sure a pressure gauge 0 600 psi range is installed downstream of the solenoid valves Adjust the burner for a smooth ignition of the main flame Disconnect the wiring to the solenoid on the Suntec B2TC 8931 oil pump Loosen and remove the knurled nut on the solenoid Adjust the screw clockwise to increase the low fire oil pressure and counterclockwise to decrease the low fire oil pressure until a smooth ignition of the oil flame is obtained and a satisfactory low fire oil flame is established Turn t
74. ge In linkage adjustments several important factors serve as guides The modulating motor must be able to complete its full travel range Restrictions will damage the motor and or linkage Lever and rod adjustments should be made with the motor in low fire position 4 20 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION The modulating motor will be stopped at the end of its stroke by an internal limit switch Combustion gas analysis indicates the air to fuel ratio and the degree of complete combustion The closer the rod comes to parallel with the lever the slower the rod moves The angles of the driven levers on the jackshaft can be adjusted to vary the rate of change The closer the rod to the hub of the lever the less distance it will travel Increasing the lever length on the damper metering unit and valve s decreases flow rate TYPICAL LINKAGE ADJUSTMENT DRIVING GAS VOLUME CONTROL VALVE TYPICAL LINKAGE ADJUSTMENT DRIVEN AIR INLET HOUSING ECREASE 656 10218 000 FIGURE 4 24 Linkage Adjustment 4 8 2 Cam Trim Adjustment After low and high fire adjustments are complete final adjustment is made with the cam assembly to obtain a good air fuel ratio throughout the entire firing range The input of combustion air is fixed at any given point in the modulating cycle The fuel input may be varied to obtain correct flue gas readings The adjustment is
75. h Operator Read and log the flame signal for both pilot and main Controls flame Notify service if readings are very high very low or fluctuating Linkages Operator Check all burner linkages for tightness Tighten if required MONTHLY Low Fan Pressure Interlock Operator Manually adjust until switch opens High and Low Gas Pres Operator Refer to instructions Manually adjust until switch opens sure Interlocks Scanner and Diffuser Operator Check inspect and clean for soot buildup Pilot Assembly Operator Check for loosening of components erosion or carbon buildup ANNUALLY Strainer Oil Units Operator Replace or clean the oil strainer element Impeller Operator Inspect and clean the combustion impeller Combustion Test Service Tech Perform a complete combustion test Adjust burner if necessary Read and log data Pilot Turndown Test Service Tech Required after any adjustment to flame scanner or pilot adjustment Operating Controls Service Tech Refer to instructions 5 8 IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 6 Troubleshooting Warning 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 Warning Disconnect and lockout the main power supply in order to avoid the hazard of electri
76. he burner off and restart to ensure smooth ignition is obtained at the set low fire pressure Replace knurled nut and tighten finger tight 4 Adjust the high fire oil input to match the maximum rating Turn the burner off and reconnect the wiring to the solenoid valve Restart the burner and allow the burner to go through ignition and low fire When the solenoid energizes the oil pump discharge pressure is at high fire pressure The high fire pressure adjustment screw is located on the oil pump body Adjust the screw clockwise to increase the pressure and counterclockwise to decrease the pressure until the correct amount of oil pressure is obtained The high fire oil pressure should be 300 psi High fire is typically 3 5 to 4 5 with less than No 1 smoke Bacharach The burner should be adjusted to provide the correct amount of fuel flow at a constant rate at high fire position as indicated on the burner data plate located inside the control panel 5 Tighten all linkages and marked settings Complete the Startup Report 4 6 2 Low High Off Low Oil Burner Adjustment The Suntec B2TD 8842 oil pump is typically incorporated and is a two stage two step oil pump The low fire pressure adjustment is 100 200 psi solenoid de energized High fire pressure adjustment is 200 300 psi Solenoid energized 1 Turn the burner switch to the ON position 2 Adjust low fire with the oil pressure regulating valve to have approximately 100
77. iency 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 Refer to Chapter 4 for instructions 3 1 7 Test Equipment The following tests should be conducted on site 1 Combustion analyzer with indication 2 U Tube manometer or pressure gauge to measure gas pressures Main and Pilot pressure and vacuum gauge for the oil burners Inclined manometer to measure draft pressures Smoke spot tester for oil burners and CO analyzer for gas fired units Voltmeter Ammeter PF to Stack thermometer and thermocouples A Warning Should a starting failure occur for any reason combustible fumes may fill the combustion chamber Never attempt to re light the burner under these conditions without first purging the chamber Read the flame safeguard manual and fully understand its content before attempting to operate this equipment If this instruction is ignored serious injury or death may result 3 2 Electrical Interference Test Prior to putting the burner into service conduct the following test to ascertain that ignition spark will not cause the flame relay to pull in IC SA 1511 02 2014 3 3 V LNV Series Manual Operation INDUSTRIAL COMBUSTION 3 2 1 Gas Fired 1 Close the pilot and main
78. ilot or main flame failure External controls connected to the flame control s limit circuit such as the boiler operating control will trigger normal burner startup and upon reaching operating set point normal burner shutdown Safety devices in the flame control s running interlock circuit such as the combustion air switch will cause an immediate safety shut down if conditions are not correct for safe operation Reference the manufacturer s literature for additional information on either the flame safeguard control or other safety controls 1 3 3 Firing Rate Controls LHL amp Full Modulation Burners LHL burners use a two position actuator and linkage to control the air and gaseous fuels oil burners control oil flow with electric valves At startup fire the air damper and fuel valves are positioned for stable low fire operation When the actuator is commanded to its second position the linkage drives the air damper and fuel valves open until high fire is reached LHL burners typically use a boiler mounted control that keeps the burner at its low fire rate to prevent thermal shock until conditions are suitable for high fire Full modulation burners are capable of firing at any rate between the burner s low and high fire limits For single point modulating systems a single rotary actuator controls both air and fuel volume via control arms and linkage attached to its shaft As the actuator rotates from low to high fire the linkage op
79. ing damper however position adjustments are made based on the fuel curve stored in the parallel positioning control s memory This in turn is increases the pressure and volume of oil at the nozzle The burner will continue to modulate as described under the combustion air heading until demand is satisfied All valves immediately close The metering valve opens to it s low fire position The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supply system On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut off valve SAFETY 5 SHUT OFF 5 NOZZLE Sk VALVES Xq MEREZA OL OIL RETURN OILINLET FLOW RATE METERING VALVE FULL MODULATION WITH SIMPLEX NOZZLE 2 22 IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 3 Operation 3 1 Preparations for Starting When the installation is complete and all electrical fuel water and vent stack connections are made make certain these connections are tight The operator should become familiar with the burner boiler controls and components 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 progr
80. inlet 6 7 8 7 1 4 7 5 8 9 1 2 Center line of FGR to mounting flange W 20 1 4 22 1 8 25 1 2 30 1 4 Center line of burner to center line of FGR X 4 5 1 4 8 7 1 4 Diameter Y 9 9 9 11 Bolt circle diameter Z 7 1 2 7 1 2 7 1 2 9 1 2 INDUSTRIAL COMBUSTION V LNV Series Table of Contents CHAPTER 1 Introduction 1 1 1 1 Overview 1 1 1 2 Description 1 1 1 3 Operating Controls 1 2 1 3 1 Control Panel 1 2 1 3 2 Flame Safeguard Controls 1 3 1 3 3 Firing Rate Controls LHL amp Full Modulation Burners 1 3 1 4 Combustion Air Handling System 1 3 1 4 1 Boiler Room Combustion Air 1 4 1 5 Firing Head 1 5 1 6 OilSystem 1 6 1 6 1 Oil System Components 1 6 1 6 2 Operation 1 9 1 7 Gas Handling System 1 9 1 7 1 Main Gas Train Components 1 10 1 7 2 Pilot Gas Train Components 1 13 1 7 3 Operation 1 13 CHAPTER 2 Installation 2 1 2 1 Application 2 1 2 2 Draft Conditions 2 1 2 3 Combustion Air Supply 2 1 2 4 Combustion Chamber Recommendations 2 2 2 4 1 Combustion Chamber Drawings Firetube Boiler Application 2 2 IC SA 1511 02 2014 i V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 3 2 4 2 Combustion Chamber Dimensions Inverted Standard Config Firetube 2 3 2 4 3 Combustion Chamber Drawings Watertube Cast Iron Boiler Applications 2 4 2 4 4 Combustion Chamber Dimensions Inverted Standard Config Wa
81. is situation For burners with the cam trim option adjust the cam screws throughout the range to obtain correct 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 3 596 to 4 5 with less than No 1 smoke Bacharach 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 correct 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 N 4 7 Combination Gas Oil System In general the combination fueled system is to be started first using oil because as a fuel oil has a greater combustion 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 gas involves balancing the input rate only against the
82. isable that the reading be less than 15 Hg vacuum Vacuum in excess of this may cause unstable firing 3 1 2 Oil Pressure 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 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 Special pressure regulating valves are available for suction pressure above 3 psi The fuel unit discharge pressure should be set at 300 psi 3 1 3 Firing Preparations for Oil Burners Prior to initial firing oil flow and pressure and temperature should be verified If the burner is a dual fuel model make certain that the main gas shutoff cock is closed and the fuel selector switch set to OIL 3 1 4 Firing Preparations for Gas Burners A representative of the gas utility should turn on the gas Determine by a test gauge upstream of the burner regulator that sufficient pressure exists at the entrance to the gas train The gas pressure regulator must be adjusted to the pressure 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 remains closed until the programmer has cycled through pre purge and
83. itch to GAS 5 Proceed with startup and adjustments using the same procedures as explained in Section 4 4 11 Do not alter the air settings set for oil Correct the levels by adjusting the butterfly valve for models V35 55 and the regulators low and high pressures for models V13 34 4 7 3 Full Modulation Combination Gas Oil Burner Adjustment 1 Set the MANUAL AUTO switch to the MANUAL position Position the manual flame control potentiometer in the CLOSED low fire position Turn the fuel selector switch to the OIL position Turn the burner switch to the ON position Proceed with startup and adjustments using the same procedures as explained in Section 4 5 3 After the system has been completely adjusted for oil firing place the burner switch to OFF and position the fuel selector switch to GAS 7 Proceed with startup and adjustments using the same procedures as explained in Section 4 4 12 Do not alter the air settings set for oil Correct the O levels by adjusting the butterfly valve o a A WO N 4 8 Modulation Control 4 8 1 Linkage Control Adjustment The linkage consists of adjustable cams levers rods and ball joints that transmit motion from the modulating motor to the air damper gas butterfly valve and oil metering unit When properly adjusted coordinated movement of the air and fuel control devices provide proper fuel air ratios through the firing ran
84. ler a few times to be sure it fits snugly in the nozzle and the spring is pressing the two parts firmly together When reinstalling be sure the nozzle is centered with the proper distance from the diffuser 5 8 Oil Nozzle The 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 clogged nozzle Inspect and clean the nozzle and screen To clean the screen swirler and tip unscrew the tip from the nozzle body Clean the 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 an identical nozzle make size and spray angel 5 4 IC SA 1511 02 2014 V LNV Series Manual 5 9 Diffuser INDUSTRIAL COMBUSTION 5 9 Diffuser The diffuser is factory set and does not require attention under normal operating conditions If fouled with carbon the diffuser should be removed for cleaning 1 First remove the electrode leads the gas pilot assembly air and oil tubes before you attempt to remove the diffuser 2 Mark the diffuser relative position to th
85. line manual gas valves 2 Start the burner and at time of 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 2 2 Oil Fired 1 Disconnect the electrical power to the burner Disconnect the electric oil safety shutoff valve Reconnect electrical power Close the pilot line manual gas valve if used Start the burner and at the time of pilot trial with just the electrical ignition system energized the flame relay should not pull in Upon completion of a successful test disconnect the power supply 7 Reconnect the oil safety shutoff valve and turn on the manual pilot gas valve 9 Reconnect the power supply and proceed with startup procedures 3 3 Gas Pilot Flame Adjustment The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator Normal setting is 4 to 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite the main flame Although it is possible to visibly adjust the size of the pilot flame obtain a proper DC volt or microamp reading of the flame signal The flame safeguard amplifier has a meter jack for this purpose At initial startup and during planned maintenance test the pilot flame signal pilot turndown and safety switch lockout 3 4 Startup Sequence
86. low fire air proving switch The burner is now ready for startup Damper is driven by the modulating actuator to a firing rate position as determined by the modulating control or manual potentiometer Actuator can complete full travel to high fire in 30 seconds Actuator will then continue to adjust firing rate position based on signals from the modulating control until demand is satisfied Damper returns to its starting position based on the 30 second closure speed of the mechanical actuator during post purge Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an in rush of gas A butterfly type gas metering valve is linked directly to the damper actuator and provides gas flow metering relative to the actuators position A manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valve low fire setting The gas valves remain in their open position As the actuator begins it s travel to the firing rate position it is also adjusting the butterfly gas metering valve increasing the flow of gas to the manifold The burner will continue to modulate as described under the combustion air heading until demand is satisfied On shut down all ga
87. lve has a visual indicator observe its position for correct operations 5 14 Electrical System Because of the many types of flame safeguard systems applicable to this equipment complete descriptions of all burner electrical systems are beyond the scope of this manual An individual electrical schematic drawing is shipped with each burner and complete operation and troubleshooting instructions are available from the various flame safeguard system manufacturers 5 14 1 Electric Motors Motor supply voltage must not vary more than 10 percent from nameplate ratings At initial startup and at least once a year thereafter check the motor current with a meter while the burner is in high fire position If the reading exceeds the nameplate rating plus service factor determine the cause and correct it immedi ately In dusty locations clean the motor regularly to assure adequate cooling Lubricate in accordance with the manufacturer s instructions 5 15 Checking Flame Failure 5 15 1 Pilot Flame Failure 1 Shut off the main fuel supply and close the gas pilot shutoff cock 2 The pilot ignition circuit will be energized at the end of the pre purge period There should be an ignition spark but no flame Since there is no flame to be detected the program relay will signal the condition 3 The ignition circuit will de energize and the control will lock out on a safety shutdown and the flame failure light will be activated 4 The
88. ly system For pumps without the internal dual pressure solenoid an external pressure relief valve and normally open solenoid valve are used SAFETY S SHUT OFF 5 VALVES Xq NOZZLE PRESSURE RELIEF VALVE A N O a oL TS VALVE PUMP LOW HIGH MODULATION OIL RETURN OIL INLET IC SA 1511 02 2014 V LNV Series Manual 2 15 INDUSTRIAL COMBUSTION Installation LOW HIGH LOW MOD LOW or 60 DAMPER PURGE COMPONENTS DESCRIPTION PRE PURGE STARTUP IGNITION RUN MODULATE Operating Sequence SHUT DOWN VARIATIONS POST PURGE Combustion Air A two blade damper is controlled by a two position spring return actuator with mechanical linkage For 60 damper purge a mechanical stop is provided on the damper to ensure sufficient air flow is provided during pre purge Power to drive the actuator is routed through a low auto switch and a remote located modulating control The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system see oil at right Damper is in its closed or low fire position For 60 damper purge this would be against the mechanical stop Damper remains in its low fire starting position Damper is driven open in 30 seconds by the two position actuator Low High Low burners will modulate from the lo
89. m the drive end e Check the pilot electrode setting Check the control linkage for proper movement of the air volume damper and fuel metering components This can be done by loosening the linkage at the actuator lever and manipulating by hand e Check the air shutter and adjust low fire setting IC SA 1511 02 2014 3 1 V LNV Series Manual Operation INDUSTRIAL COMBUSTION 3 1 1 Oil Flow If the oil supply tank is below the level of the fuel oil 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 lubrication 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 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 investigation is required A vacuum or compound pressure vacuum gauge should be installed at the suction port of the pump It is adv
90. made to the metering cam by means of the 14 adjusting screws which are turned in clockwise from the hex socket end to increase the flow of fuel and out counterclockwise from the hex socket end to decrease it A 3 32 hex key is required It will be necessary to cut off the short end of a hex key to approximately 3 8 to adjust the first two socket head setscrews at the low fire position Take a combustion analysis at various points of the cam profile Adjustment can be made without cycling the burner then operate the automatic modulating cycle to assure satisfactory results Tighten the locking setscrews NOTE It is essential that the cam spring cam follower bearing wheel and cam follower arm at the pivot point be greased sparingly every month to ensure smooth operation of the cam assembly Regular automotive bearing grease should be used IC SA 1511 02 2014 4 21 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION SETPOINT LOCKING MODULATING SCREWS LOW FIRE START POSITION OF ROLLER GUIDE MUST FALL WITHIN THESE LIMITS 4 GUIDE LESS SPRING TENSION CAM SETPOINT ADJUSTMENT SCREWS RETURN SPRING INCREASE DECREASE MORE DECREASE SPRING E TENSION INCREASE INCREASE DECREASE 656 10218 000 FIGURE 4 25 Cam Trim Adjustment 4 8 3 Parallel Positioning Adjustment For parallel positioning systems refer to the control manufacturer s documentation and to the
91. mounted by the installer as close to the butterfly valve as practical If a pre piped and wired gas train is ordered the components upstream of the first safety shutoff valve are shipped loose These components should also be mounted by the installer 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 connected upstream of the main gas regulator If a reducing bushing is required between the house piping and the burner piping it should be close to the burner 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 Section 3 2 9 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 e Electrical terminals in the control panel and on all electrical components Pipe fittings and unions Tubing connections e Nuts bolts screws 2 Open all necessary oil shutoff valves Do not run pumps or fuel unit without oil 3 Before connecting electrical current to any component be sure the voltage is the same as that specified on component nameplates 4 Before burner operation be sure all motors are rotating in the proper direction 5
92. n Straight oil burners VL13 55 employ direct spark ignition where the oil is ignited when the oil solenoid valves open and the spray contacts the electrical discharge from the direct spark electrodes Gas oil VLG burner use a proven gas pilot where the oil is ignited when the oil solenoid valves open and the oil spray contacts the established gas pilot flame On full modulation units the modulating actuator varies the oil metering valve setting The metering valve located in the return oil loop reduces the firing rate by opening and allowing more oil to return to the supply tank Conversely at high fire the valve is closed forcing all oil to exit the spray nozzle On LHO LHL units bypass piping routes most of the oil back to the storage tank while at low fire At high fire a valve blocks the return loop and forces all the oil through the nozzle 1 7 Gas Handling System Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold Firing rate is determined by the size and number of ports by manifold pressure and by combustion zone pressure The firing rate is regulated by a rotary butterfly type throttling valve at the manifold inlet The valve is actuated by adjustable linkage from the modulating motor Depending upon specific requirements one or two gas safety shutoff valves are provided for installation in the gas train upstream of the butterfly IC SA 1511 02 2014 1 9 V LNV Seri
93. n 7 1 7 2 Duct Sizing 7 2 7 3 FGR Shutoff Valve 7 3 IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION 7 4 Control Valve 7 3 7 4 1 Low NOx Full Modulation Combination Gas Oil Burner Adjustment 7 4 7 5 Air FGR Damper Assembly 7 5 7 6 Stack Temperature Interlock 7 5 7 7 Blast Tube Temperature Interlock 7 5 WARRANTY POLICY STARTUP SERVICE REPORT vi IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 1 Introduction 1 1 Overview V series burners are assembled wired and tested at the factory They are listed by the Underwriters Laboratory UL CSD 1 NFPA 85 Factory Mutual FM including the National Electrical Code NEC and associated insurance underwriters Where applicable the Canadian Gas Association CGA B149 and the Canadian Standards Association CSA B140 codes shall prevail Other regulatory agency control options are available Z Caution Only factory authorized burner service personnel should startup adjust or service this equipment Burner linkages cams fuel metering valves and positioning motors have not been pre set by the factory for proper combustion and must be set by a qualified and authorized technician Failure to follow this procedure could result in property damage and personal injury The operator must be familiar with the individual functioning of all controls to understand the operatio
94. n 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 increments to the high fire position Check high fire at this point using combustion instruments High fire combustion analysis typically is 3 to 4 Os 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 setting CO levels should be less than 400 ppm on an air free basis at all firing rates with 50 ppm as the target value When conditions covered above are assured refer to Sections 3 9 and 3 10 3 8 2 Oil Burners 1 The fuel selector switch should be set to OIL and 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 IC SA 1511 02 2014 3 7 V LNV Series Manual Operation INDUSTRIAL COMBUSTION 2 Set the ON OFF switch to ON The burner will start and pre purge After pre purge the ignition transformer will di
95. ndard Gas Train Pipe Size in Min Gas Pressure w c Blower Motor Volt PH 60 Hz 0 5 3 4 1 2 1 9 2 115 230 1 LNV 17 1 1 700 12 1 LNV 20 1 2 000 14 3 0 6 3 4 1 2 1 1 3 4 1 11 7 BLA 115 230 1 14 7 115 230 1 20 2 115 230 1 A 115 230 1 LNV 25 1 1 4 3 4 11 2 115 230 1 LNV 30 2 1 5 115 230 460 3 LNV 34 2 LNV 35 2 3 500 25 0 LNV 40 2 4 000 28 6 83 95 1 9 2 0 1 2 1 4 1 2 w o o co r LNV 42 2 4 200 30 0 100 1 1 2 LNV 45 2 5 1 6 1 2 a R RT RR gt 115 230 460 3 8 1 115 230 460 3 10 4 115 230 460 3 11 5 208 230 460 3 ALAR 208 230 460 3 LNV 50 2 2 0 1 2 208 230 460 3 LNV 54 3 2 4 3 4 208 230 460 3 LNV 55 3 a a wo ow a 5 3 4 2 5 3 4 LNV 70 3 ABB RT AR A 208 230 460 3 17 6 208 230 460 3 19 4 208 230 460 3 A LNV 80 3 3 2 LNV 84 3 3 5 LNV 90 3 LNV 100 4 10 000 71 4 LNV 105 4 10 500 75 0 LNV 110 4 4 0 ABB RIT RR 2 1 2 20 5 460 3 2 1 2 447 460 3 2 1 2 LNV 120 4 21 2 LNV 126 4 LNV 147 4 2 2 a o gt Input is based on fuel BTU content listed furnace pressure and altitude of 2 000 feet or less If altitude gt 2 000 feet and lt 8 000 feet derate capacity 4 per 1 000 feet over 2 000 Consult factory for higher altitudes If furnace pressure exceeds listed value de
96. ned to GAS Actuate the manual reset button of the flame safeguard control to close the safety switch contacts Set the MANUAL AUTO switch in the MANUAL position Set the manual potentiometer in the low fire position Open the gas pilot cock Set the ON OFF switch to ON The burner will start and pre purge After pre purge the ignition transformer and the gas pilot solenoid are energized Before proceeding conduct electrical interference and pilot turndown tests if not previously done see Section 3 2 On initial startup it is recommended that the main gas shutoff cock remains closed until the programmer has cycled through pre purge and pilot sequence Then determine that the main gas valve opens When this is confirmed turn the burner switch OFF and let the programmer finish its cycle 3 6 IC SA 1511 02 2014 V LNV Series Manual Operation INDUSTRIAL COMBUSTION 9 Check to see that the gas valve has closed tightly If ignition does not occur turn the burner switch OFF and allow the programmer to recycle for a new ignition trial 10 Turn the burner ON and after pilot ignition when the flame relay pulls in the slow opening motorized main gas valve is energized The main flame should ignite at this time The gas valve and air damper continue advancing until high fire is reached 11 Do not repeat unsuccessful light off attempts without rechecking burner and pilot adjustm
97. ng return actuator with mechanical linkage For 60 damper purge a mechanical stop is provided on the damper to ensure sufficient air flow is provided during pre purge Damper position is controlled by a two position spring return actuator with mechanical linkage The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system see oil at right COMPONENTS DESCRIPTION Damper is in its closed or low fire position For 6096 damper purge this would be against the mechanical stop PRE PURGE 5 STARTUP Damper remains in its low fire gt IGNITION starting position o Damper is driven open in 30 seconds by the two position RUN actuator Low High Off burners MODULATE have no provision to modulate 8 the burner once high fire rate has been achieved Damper returns to its start position based on the 25 second closure speed of the mechanical actuator SHUT DOWN POST PURGE VARIATIONS LOW HIGH OFF OPERATION LOW or 60 DAMPER PURGE Two safety shut off valves are provided to initiate the flow of gas The primary is a diaphragm or motorized type On diaphragm gas valves the time to open can be adjusted by a bleed valve On models with motorized valves the time to open is fixed at 13 seconds A butterfly type gas metering valve is linkaged directly to the damper actuator and provides gas flow metering during the drive to the high p
98. ng to the supply system The safety shut off oil valves remain open The pump s solenoid is energized by the auxiliary switch within the damper actuator as it opens the air damper Oil pressure is then increased based the pumps high pressure setting The burner will remain at high fire until demand is satisfied All valves immediately return to their startup or de energized position The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supply system For pumps without the internal dual pressure solenoid an external pressure relief valve and normally open solenoid valve are used S SAFETY SHUT OFF S VALVES 1 NOZZLE PRESSURE RELIE VALVE AI N O OIL VALVE 5 OIL RETURN OIL INLET LOW HIGH MODULATION 2 14 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION LOW HIGH OFF OPERATION OPEN DAMPER PURGE Combustion Air COMPONENTS DESCRIPTION PRE PURGE STARTUP IGNITION RUN MODULATE Operating Sequence SHUT DOWN VARIATIONS POST PURGE A two blade damper is controlled by a two position spring return actuator with mechanical linkage The actuator also contains a limit switch which is used to actuate the second stage of the oil supply system see oil at right A second external switch ensures the damper has
99. ns and procedures described in this manual 1 2 Description The Industrial Combustion V 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 burner and control panel components require little attention except for occasional cleaning IC SA 1511 02 2014 1 1 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION The burners are available in the following configurations Standard Configuration Optional Configuration On Off Low High Off LHO Low High Low LHL or Full Modulation Low High Off LHO Low High Low LHL or Full Modulation V70 168 Full Modulation 1 3 Operating Controls 1 3 1 Control Panel The burner control panel may be integral to the burner or remote and 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 The following table lists typical panel items Some or all of the items may be provided depending on the burner configuration selected Control Description On Off Burner Switch To manually turn the burner on or off Fuel Selector Switch Gas Off Oil Gas position Selects gas as the firing fuel Off position Burner is off Oil position Selects oil as the firing fuel Control Circuit
100. ometer is at the OPEN position 9 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 396 to 496 O with less than 50 ppm CO as a target value 10 Modulate the burner to low fire Verify the readings The burner should be adjusted to provide correct fuel flow at a constant rate as indicated on the burner data plate 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 5096 below and 5096 higher than normal pressure respectively 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 5 10 Low NOx Full Modulation Combination Gas Burner Adjustment LNV burners are equipped with an FGR flu gas recirculation valve to lower the NOx emissions An adjustable cam is provided to adjust the FGR valve position throughout the firing range on gas Follow the steps for gas from Section 4 4 12 with the following additions 1 Make sure the FGR v
101. on efficiency and fuel and air input adjustments The system should be adjusted to a minimum excess air quantity that provides low levels of unburned fuel with sufficient remaining O2 to cope with normal atmospheric and fuel related changes Unburned fuel is measured as CO when burning natural gas and smoke spots when burning oil The burner should be set up and maintained to yield smoke spot levels less than No 1 spot ASTM D2156 Shell Bacharach Scale to minimize soot and buildup in the boiler Ah Warning Keep fingers away from the air inlet area of the damper The damper is actuated with sufficient force to cause severe injury IC SA 1511 02 2014 4 23 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION FRONT AIR SHUTTER AIR SHUTTER FIGURE 4 26 Front and Rear Shutters 4 24 IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 5 Maintenance 5 1 Overview Warning Any cover plates enclosures or guards anchored to the burner or any burner related equipment must remain in position at all times Only during maintenance and service shutdown can these cover plates enclosures or guards be allowed to be removed They must be replaced and securely anchored before testing adjusting or running the burner or burner related equipment Ab Warning Only factory authorized burner service personnel should start up adjust or service
102. on must be with the MANUAL AUTO switch selector on AUTO In automatic operation the operating cycle always proceeds sequentially 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 programmer used During the run cycle burner input is regulated to the load demand by the modulating pressure or temperature control on the boiler The burner will continue to modulate until the operating pressure or temperature is reached Programmer control operation should be tested when the burner is initially placed into service when a control is replaced and at scheduled intervals in the maintenance program Refer to Chapters 4 and 5 3 10 Shutdown When the operating limit control setting is reached or the burner switch is turned OFF the following sequence occurs 1 The fuel valve s de energize and flame extinguishes The blower motor continues running during post purge if equipped with post purge feature 2 At the end of 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 interruption combustion or atomizing air pressure below minimum level tripped circuit breakers blown fuses or other interlock devices Check for the cause and correct the situation
103. on the pump s low pressure setting Excess oil is flowing through an internal relief valve and returning to the supply system The safety shut off oil valves remain open The pump s solenoid is energized by the aux switch within the damper actuator as it opens the air damper Oil pressure is then increased based the pump s high pressure setting The actuator begins its travel to the high fire position opening the gas metering valve The burner will modulate from low to high as described in the combustion air column SHUT DOWN POST PURGE Damper returns to its start position based on the 25 second closure speed of the mechanical actuator On shut down all gas valves close within 1 second The butterfly valve closes in 25 seconds with the two position actuator All valves immediately return to their startup or de energized position The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supply system VARIATIONS None None For pumps without the internal dual pressure solenoid an external pressure relief valve and normally open solenoid valve are used SAFETY S SHUT OFF S VALVES NOZZLE m PRESSURE RELIEF VALVE N O OIL S VALVE LIGHT LOW HIGH MODULATION PUMP e OIL RETURN OIL INLET IC SA 1511 02 2014 V LNV Series Manual
104. ond The butterfly valve closes in 25 seconds with the two position actuator None Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle The oil pump has a built in solenoid controlled two level pressure regulating system Low and high flow rates are set on the pump based on pressure and the nozzle s flow rating SAFETY 5 SHUT OFF 5 gt VALVES K m 2 LEVEL PRESSURE SOLENOID NOZZLE LOW HIGH MODULATION WITH 2 LEVEL PUMP PRESSURE OIL RETURN OIL INLET The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s low pressure setting Excess oil is flowing through an internal relief valve and returning to the supply system The safety shut off oil valves remain open The pump s solenoid is energized by the auxiliary Switch within the damper actuator as it opens the air damper Oil pressure is then increased based the pumps high pressure setting The burner will remain at high fire until demand is satisfied All valves immediately return to their startup or de energized position The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supp
105. optimize burner performance A two bladed damper is controlled by independent parallel positioning actuator The remote mounted modulating control From its closed position the damper is driven open by a signal from the parallel positioning control The damper will remain open for the duration of the pre purge cycle Damper returns to the low fire position in preparation for startup Damper is driven by its parallel positioning actuator to a firing rate position as determined by the parallel positioning control The actuator and parallel positioning control will then continue to adjust the damper and fuel actuators position based on signals from remote sensors until demand is satisfied Damper returns to its closed position during or following post purge None Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an in rush of gas A butterfly type gas metering valve is directly coupled to a parallel positioning actuator A manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting The gas valves remain in their open position The metering valve and actuator increases the flow of gas to the manifold in conjunction wi
106. osition A manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting The gas valves remain in their open position The actuator begins it s travel to the high fire position opening the gas metering valve The burner will remain at high fire until demand is satisfied On shut down all gas valves close within 1 second The butterfly valve closes in 25 seconds with the two position actuator Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle The oil pump has a built in solenoid controlled two level pressure regulating system Low and high flow rates are set on the pump based on pressure and the nozzle s flow rating SAFETY S SHUT OFF S gt VALVES sq fm 2 LEVEL PRESSURE SOLENOID OIL RETURN OIL INLET NOZZLE LOW HIGH MODULATION WITH 2 LEVEL PUMP PRESSURE The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s low pressure setting Excess oil is flowing through an internal relief valve and returni
107. perative 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 or atomizing air 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 1511 02 2014 6 3 V LNV Series Manual Troubleshooting INDUSTRIAL COMBUSTION Problem Possible Causes Pilot Flame but No 1 Insufficient pilot flame Main 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 No fuel Broken loose or missing oil pump coupling d Main oil valve inoperative e Check oil nozzle gun and lines Flame detector defective sight tube obstructed or lens dirty Insufficient or no voltage at main fuel valve circuit terminal
108. position Not Operate 2 Linkage loose or jammed 3 Motor does not drive to open or close during pre purge or close on burner shut down 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 1511 02 2014 6 5 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 7 LNV Series FGR System NOTE Check all burner and FGR wiring before operating the unit Turn all power off when working with any wiring Power must be turned off at the disconnect to the boiler Boiler operation and FGR adjustment must be done by a qualified Industrial Combustion service representative 7 1 Description The LNV burner is designed to guarantee low emissions of lt 30 ppm NO and lt 50 ppm CO corrected at 3 when firing natural gas The burner features an induced Flue Gas Recirculation system FGR The flue gases of the boiler are recirculated through the burner using the combustion air impeller to draw the exhaust gases from the stack through the FGR duct and mix them with incoming fresh air An electrically actuated damper controls the flow of FGR to fine tune the FGR fresh air ratio Ducting from the stack or boiler to the burner is done by o
109. prevent an in rush of gas butterfly type gas metering valve is linked directly to the damper actuator and provides gas flow metering during the drive to the high position manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting The gas valves remain in their open position The actuator begins its travel to the high fire position opening the gas metering valve The burner will modulate from low to high as described in the combustion air column Cil Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle The oil pump has a built in solenoid controlled two level pressure regulating system Low and high flow rates are set on the pump based on pressure and the nozzle s flow rating SAFETY 5 SHUT OFF 5 VALVES K fm 2 LEVEL PRESSURE SOLENOID OIL RETURN OIL INLET NOZZLE L LIGHT OIL PUMP LOW HIGH MODULATION WITH 2LEVEL PUMP PRESSURE The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based
110. pring drives it to the low fire position All gas only VG V13 55 models 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 pressure that is required to fire the burner at its rated capacity To adjust the regulator unscrew the cap located on the top and turn the adjustment screw clockwise to increase pressure or clockwise to decrease pressure 3 Turn the burner switch to the ON position The burner will start in the low fire position 4 After a few seconds the analyzer should have an accurate reading of the present in the flue gas Normally Os levels are set between 4 to 6 at low fire for standard turndown systems on gas and 6 to 996 O for high turndown systems with the target value of less than 50 ppm CO To obtain the proper readings adjust the air shutter and low fire regulator pressure 5 Operate the boiler at low fire until it is up to operating pressure steam or temperature hot water e 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 m
111. r VLG Gas Oil V120 168 Watertube Cast Iron 4 12 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 4 5 Gas System Refer to the burner data plate located inside the control panel door The nameplate will list the following burner information burner and control voltage phase cycle motor amperage 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 For most efficient combustion allow the boiler to fully warm up before making adjustments Refer to the boiler instruction manual for the boiler control settings 4 5 1 Gas Pressure Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas train and furnace pressure while running at full input Refer to nameplate inside control panel for gas pressure requirements at train inlet and manifold The pressures listed are based on nominal 1000 Btu cu ft natural gas at elevations up to 2000 feet above sea level 4 5 2 Gas Flow The volume of gas is measured in cubic feet as determined by a meter reading The gas flow rate required depends on the heating value Btu cu ft
112. rankcase oil or any oil containing gasoline INDUSTRIAL COMBUSTION Motor ratings for gas only or gas oil burners using a remote oil pump Standard Specifications for VG VL VLG Series Gas 2 Oil Gas Oil Configuration Gas 2 Oil Standard Input Input Furnace Remote GasTrain Min Gas Burner MBtu US Pressure Oil Pump PipeSize Pressure Blower Motor Model hr GPH W C Motor HP in w c Volt PH 60 Hz V 13 1 1 300 9 3 1 2 1 8 6 9 2 115 230 1 15 1 1 500 10 7 1 2 1 44 4 11 78 115 230 1 17 1 1 700 12 1 1 2 1 44 3 14 75 115 230 1 V 20 1 2 000 143 1 2 1 49 7 20 28 115 230 1 V 21 1 2 100 15 0 1 2 1 21 5 22 15 115 230 1 V 25 1 2 500 17 9 1 2 11 2 96 1045 115 230 1 V 30 1 3 000 21 4 1 2 2 8 7 115 230 1 V 34 1 3 400 24 3 1 2 2 10 3 115 230 1 V 35 2 3 500 25 0 83 1 9 1 1 2 1 2 2 8 1 115 230 1 V 40 2 4 000 28 6 95 1 2 1 1 2 1 2 2 10 4 115 230 1 V 42 2 4 200 30 0 1 2 2 11 5 208 230 460 3 V 45 2 4 500 32 1 1 2 2 10 8 208 230 460 3 V 50 2 5 000 35 7 3 4 2 13 6 208 230 460 3 V 54 2 5 400 38 6 3 4 2 19 2 208 230 460 3 V 55 2 5 500 39 3 3 4 2 19 7 208 230 460 3 V 60 3 6 000 42 9 3 4 2 17 6 208 230 460 3 V 63 3 6 300 45 0 3 4 2 19 4 208 230 460 3 V 70 3 7 000 50 0 3 4 2 1 2 15 8 208 230 460 3 V 80 3 8 000 57 1 1 2 1 2 15 1 208 230 460 3 V 84 3 8 400 60 0 1 2 1 2 15 5 460 3 V 90 3 9 000 64 3 1 1 2 2 1 2 17 4 460 3 V 100 3 10 000 71 4 1 1
113. rate capacity 5 for every 0 5 w c of pressure in excess of stated Consult factory if derate exceeds 20 Gas input is based on natural gas with 1 000 BTU cu ft 0 60 gravity For total pressure at manifold add furnace pressure Oil input based on 140 000 BTU gal Consult factory for 50 Hz applications INDUSTRIAL COMBUSTION V Series Standard Dimensions Uncontrolled NOx Configuration e d R HDI s Accompanying dimensions are for layout purposes only A 559 BE d e o o D 9 Burner Frame Size amp Model Number DIM Size 1 Size 2 Size 3 Size 4 Overall length A 37 1 4 40 3 8 45 1 4 51 1 8 Center line to right side standard M 14 13 5 8 16 7 8 21 7 8 Center line to left side standard N 12 7 16 13 7 8 15 1 4 15 1 4 Center line to right side inverted N 12 7 16 13 7 8 15 1 4 15 1 4 Center line to left side inverted 14 13 5 8 16 7 8 21 7 8 Center line to top standard J 9 1 2 9 1 8 8 3 8 9 3 4 Center line to bottom standard K 11 3 4 14 7 16 18 5 8 19 1 4 Center line to burner support standard P 11 3 4 14 7 16 18 5 8 19 1 4 Center line to top inverted R 28 30 5 8 34 3 4 35 1 2 Center line to CL of main gas inlet inverted Q 6 7 8 8 7 8 10 1 8 11 3 4 Extension standard C 4 4 4 5 Extension maximum C 5 5 5 6 Diameter D 8 1 4 10 11 1 2 13 5 8 Panel box depth G 7 3 8
114. rate is fixed based on pump oil pressure and the simplex nozzle s flow rating SAFETY S 5 SHUT OFF gt lt VALVES gt lt NOZZLE LIGHT PUMP OIL INLET ON OFF MODULATION OIL RETURN PRE PURGE The damper provided with on off units is adjusted at the time the burner is installed and is fixed in place The open damper STARTUP IGNITION position allows a fixed rate of air flow during all aspects of burner operation while the blower motor is operational RUN MODULATE Operating Sequence SHUT DOWN POST PURGE Valves are closed Valves open To prevent a surge of gas from reaching the manifold the primary gas valves open at a slowed rate The valves are closed The oil pump is operating with pre purge but oil is flowing through an internal relief and returning to the supply system The valves open allowing pressurized oil to flow from the pump to the nozzle Valves remain open Valves remain open On shut down all gas valves close within 1 second Valves close immediately The oil pump is operating with post purge but oil is once again relieved to the supply system VARIATIONS None None None IC SA 1511 02 2014 V LNV Series Manual 2 13 INDUSTRIAL COMBUSTION Installation Combustion Air A two blade damper is controlled by a two position spri
115. rect spark If the flame detector proves the presence of a satisfactory pilot the programmer will proceed to main flame ignition 3 Make initial air shutter settings for smooth ignition Return line oil pressure should be set according to guidelines 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 Set the oil low fire rate by adjusting the oil return pressure and air linkage Using the combustion analysis instrument adjust the low fire Typical combustion analysis for low fire is 5 to 6 4 When low fire is adjusted 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 5 After the boiler has reached operating temperature or pressure turn the potentiometer switch in small increments 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 high fire at this point u
116. ron IC SA 1511 02 2014 V LNV Series Manual 4 10 Adjustments INDUSTRIAL COMBUSTION 5 32 BETWEEN INNER EDGES OF ELECTRODE WIRES 7 16 FROM CENTER 25 NOZZLE TIP OF OIL NOZZLE TIP TO OUTER EDGE OF 4 TO BOTTOM EDGE ELECTRODE WIRES OF ELECTRODE WIRES 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 1 89 REAR FACE OF DIFFUSER TO 656 10215 000 FRONT FACE OF FIGURE 4 17 Drawer Assembly for VL Oil Only V35 55 Watertube Cast Iron 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 1 81 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 16 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 FIGURE 4 19 Drawer Assembly for VG Gas Only V60 110 Watertube Cast Iron IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 1 83 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10215 000 FIGURE 4 20 Drawer Assembly for VLG Gas Oil V60 110 Watertube Cast Iron 1 92 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4 21 Drawer Assembly for VG Gas Only V120 168 Watertube Cast Iron 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 1 92 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10215 000 FIGURE 4 22 Drawer Assembly fo
117. roper fuel air ratio Excessive air leaks in the combustion chamber Improper fuel oil temperature 4 2 3 Test Equipment The following test equipment should be used to set up and adjust the burner correctly 1 Combustion analyzer with O 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 Smoke spot tester for oil burners and CO analyzer for gas fired units Voltmeter Ammeter Stack thermometer and thermocouples o 4 2 4 Gas Adjustments Low fire combustion analysis is 6 to 9 and less than 0496 CO 400 ppm A high fire reading typically is 396 to 5 and less than 04 CO The V series burners are capable of operating at low excess air and less than 50 ppm CO levels at all firing rates 4 2 5 Fuel Oil Adjustments Adjust for a clean fire Typically for No 2 oil Oa is 5 to 696 at low fire and 3 5 to 4 5 at high fire 4 3 Electrical Interference Test Prior to putting the burner into service conduct the following test to ascertain that ignition spark will not cause the flame relay to pull in 4 3 1 Gas Fired 1 Close the pilot and main line manual gas valves 2 Start the burner and at time of pilot trial with just the electrical ignition system energized the flame relay should not pull in be energized 4 2 IC SA 1511 02 2014 V LNV S
118. s Pressure Switch A pressure actuated switch that remains closed when gas pressure is below a Models V30 168 selected setting Should the pressure rise above the setting the switch contacts will open causing the main gas valve s to close This switch requires manual reset after being tripped Low Gas Pressure Switch A pressure actuated switch that remains closed when gas pressure is above a Models V30 168 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 NOTE The pilot gas supply connection must be upstream of the main gas pressure regulator NOTE Gas train components upstream of the butterfly valve are shipped loose and are to be mounted by the installer If a pre piped and wired gas train is ordered the components upstream of the first safety shut off valve are shipped loose and must be mounted by the installer 1 10 IC SA 1511 02 2014 V LNV Series Manual Introduction INDUSTRIAL COMBUSTION OUTPUT TO BURNER COCK SHUTOFF TO INPUT FROM SUPPLY SHUTOFF COCK 571 0012 FIGURE 1 9 Typical Gas Train for On Off System V13 25 OUTPUT TO BURNER SHUTOFF _ COCK REGULATOR MAIN GAS gt VALVE MAIN GAS SHUTOFF VALVE COCK TO BURNER x PILOT REGULATOR 9 INPUT PILOT FROM SUPPLY VALVE PILOT SHUTOFF COCK 571 0013 FI
119. s valves close within 1 second The butterfly valve closes in 30 seconds with the damper actuator Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to a return flow nozzle In the return line from the nozzle an adjustable oil metering valve limits the amount of oil allowed to return to the pump The metering valve is connected to the damper actuator with mechanical linkage SAFETY S S SHUT OFF VALVES 5 DX FLOW RATE METERING VALVE NOZZLE FULL MODULATION WITH RETURN FLOW NOZZLE LIGHT OIL OIL RETURN OILINLET The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s pressure setting less the volume of oil returning through the metering valve The safety shut off oil valves remain open As the actuator begins it s travel to the firing rate position it is also adjusting the oil metering valve decreasing the amount of oil allowed to return to the pump This in turn is increasing the pressure and volume of oil at the nozzle The burner will continue to modulate as described under the combustion air heading until demand is satisfied All valves immediately
120. sing combustion instruments High fire combustion analysis typically is 3 5 to 4 Ob 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 9 and 3 10 3 8 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 combustion air requirement than natural gas Refer to the gas burner or oil burner adjustment procedures and Chapter 4 Once the adjustments are set for oil shutdown the burner and restart and adjust the natural gas fuel Do not readjust the air dampers 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 9 and 3 10 NOTE Size 1 amp 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 motor ensure that there is proper
121. sition e Start and stop the burner several times to ensure proper pilot setting NOTE Refer to the flame safeguard control manual instructions 4 4 3 Direct Spark Oil Only VL Adjustment V13 55 Oil only VL models V13 55 are equipped with a direct spark ignition Remove the oil drawer assembly and check the electrode settings and the nozzle size 5 32 BETWEEN INNER EDGES OF ELECTRODE WIRES 25 FROM 7 16 FROM CENTER NOZZLE TIP TO OF OIL NOZZLE TIP OUTER EDGE OF TO BOTTOM EDGE ELECTRODE WIRES OF ELECTRODE WIRES 656 10213 000 FIGURE 4 1 Direct Spark Ignition Oil Only VL V13 55 4 4 4 Burner Pilot Settings To ensure reliable and safe burner 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 1 Lockout and tag the electrical power supply to the burner to prevent inadvertent operation during checking or maintenance activities 2 Disconnect the high voltage power supply from the oil spark ignition electrodes if installed 3 Disconnect the oil piping from the side of the firing head 4
122. struction manual Check the pilot electrode setting The pilot is accessible by loosening the four screws on the side of the firing head and disconnecting the gas line An ultra violet flame sensor electrical spark interference test must be performed after final adjustment See Section 4 3 of this chapter for additional information 4 4 2 Gas 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 0 to 10 W C or a manometer is installed in the pilot line to monitor the pilot gas pressure IC SA 1511 02 2014 4 3 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION 2 When the pilot comes on put the programmer timer on pilot hold by placing the RUN TEST switch on the flame safeguard to the TEST position 3 Check the flame signal strength Adjust the flame signal by increasing or decreasing pilot gas pressure with the regulator spring Normal setting is 4 to 6 W C 4 Perform a pilot turndown test by reducing the pilot pressure very slowly until the scanner looses sight of the flame and gives a flame lockout then reset the adjustment to normal level Note the minimum pressure level 5 After adjusting the pressure back to normal level set the programmer to the RUN position Main flame will come on and the burner is in the low fire po
123. 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 troubleshoot before restarting the unit Follow the instructions in Chapter 3 for starting and operating 6 2 IC SA 1511 02 2014 V LNV Series Manual 6 3 Troubleshooting INDUSTRIAL COMBUSTION 6 3 Troubleshooting Problem 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 circuit not completed no voltage at end of limit circuit program relay terminal a Pressure or temperature is above setting of operation control b Water below required level Low water light and alarm horn should indicate this condition Check manual reset button if provided on low water control c Fuel pressure must be within settings of low pressure and high pressure switches d 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 Ino
124. t 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 Never attempt to circumvent any of the safety features A Warning The cause for loss of flame or any other unusual condition should be investigated and corrected before attempting to restart Failure to do so may result in serious personal injury or death A Warning Do not repeat unsuccessful lighting attempts without rechecking the burner and pilot adjustments Damage to the boiler or serious person injury or death may result A Warning 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
125. tertube 2 5 2 5 Installation 2 6 2 6 Packing Plastic Insulation Around Oven If Dry Oven Supplied 2 7 2 7 Oil Piping 2 8 2 7 1 Pressure Atomization Oil Piping 2 8 2 7 2 Two Pipe Single Burner Operation 2 8 2 7 8 Suction Line Sizing 2 8 2 7 4 Return Line Sizing 2 8 2 7 5 Two Pipe Multiple Burner System 2 9 2 8 Gas Piping 2 11 2 9 Installation Checklist 2 12 2 10 Firing Modes 2 13 Operation 3 1 3 1 Preparations for Starting 3 1 3 1 1 Oil Flow 3 2 3 1 2 Oil Pressure 3 2 3 1 3 Firing Preparations for Oil Burners 3 2 3 1 4 Firing Preparations for Gas Burners 3 2 3 1 5 Burner Settings 3 3 3 1 6 Combustion Settings 3 3 3 1 7 Test Equipment 3 3 3 2 Electrical Interference Test 3 3 3 2 1 Gas Fired 3 4 3 2 2 Oil Fired 3 4 3 3 Gas Pilot Flame Adjustment 3 4 3 4 Startup Sequence 3 4 3 5 Automatic Shutdown 3 5 3 6 Manual Shutdown 3 5 IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION CHAPTER 4 3 7 Safety Shutdown 3 5 3 8 Startup and Operating 3 6 3 8 1 Gas Burners 3 6 3 8 2 Oil Burners 3 7 3 8 3 Combustion Gas Oil Burners 3 8 3 8 4 Fuel Chart Comparison for Excess Air 3 9 3 9 Normal Operation 3 10 3 10 Shutdown 3 10 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
126. th the opening damper however position adjustments are made based on the fuel curve stored in the parallel positioning control s memory The burner will continue to modulate as described under the combustion air heading until demand is satisfied On shut down all gas valves close within 1 second The butterfly valve returns to it s starting position None Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to a return flow nozzle In the return line from the nozzle is an adjustable oil metering valve which limits the amount of oil allowed to return to the pump The metering valve is direct coupled to a parallel positioning actuator SAFETY 5 SHUT OFF NOZZLE VALVES 5 FLOW RATE METERING VALVE Ye OIL RETURN OIL INLET FULL MODULATION WITH RETURN FLOW NOZZLE The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s pressure setting less the volume of oil returning through the metering valve The safety shut off oil valves remain open The metering valve and actuator decreases the flow of oil returning to the pump in conjunction with the open
127. thers All FGR duct piping should be covered with a minimum of 2 of insulation The following controls are used in the FGR duct for safe operation of the system 656 10219 000 FIGURE 7 1 General Layout of the Burner IC SA 1511 02 2014 7 1 V LNV Series Manual LNV Series FGR System INDUSTRIAL COMBUSTION 7 2 FGR Duct Sizing Ducting from the stack or boiler to the burner is done by others Typical sizing for the FGR ducts is shown below All FGR duct piping should be covered with a minimum of 2 of insulation The following controls are used in the FGR duct for safe operation of the system Minimal Pipe Size Schedule 10 Pipe in Maximum Feet From Burner to Boiler Stack LNV SIZE 1 LNV SIZE 2 LNV SIZE 3 LNV SIZE 4 HR RI Equivalent Lineal Feet for Schedule 10 Pipe Fittings ft Pipe Fittings Nominal Pipe Size 10 45 Elbow 90 Elbow LG R 90 Elbow Schedule 40 pipe pressure drops will be slightly higher greater F G R PIPING BURNER F G R CONNECTION E PLATE BOILER STACK F G R CONNECTION PLATE BOILER STACK BURNER FIGURE 7 2 FGR Connection to Boiler Top View 7 2 IC SA 1511 02 2014 V LNV Series Manual LNV Series FGR System INDUSTRIAL COMBUSTION 7 3 FGR Shutoff Valve The FGR shutoff valve is located as
128. to disconnect all power 5 2 1 Programming Control This control requires no adjustment nor should any attempt be made to alter contact settings or timing logic Those programmers with contacts may require occasional cleaning If so follow instructions given in the manufacturer s bulletin Never use abrasive materials The manufacturer s bulletin also contains troubleshooting information The flame detector lens should be cleaned as often as conditions demand A periodic safety check procedure should be established to test the complete safeguard system Tests should verify safety shutdown with a safety lockout upon failure to ignite the pilot or he main flame and upon loss of flame Each of these conditions should be checked on a scheduled basis The safety check procedures are contained in the manufacturer s bulletin 5 3 Air Handling System A balanced blower wheel requires minimal maintenance Check for dirt buildup and clean the blades as required Inspect the impeller hub and blades for cracks Replace if any are noticed Make sure the air inlet cone fits inside the impeller BLOWER MOTOR ACCESS COVER IMPELLER WHEEL S FLEXIBLE 656 10212 000 COUPLING FIGURE 5 1 Air Handling System 5 2 IC SA 1511 02 2014 V LNV Series Manual 5 4 Impeller and Inlet Cone INDUSTRIAL COMBUSTION 5 4 Impeller and Inlet Cone Proper clearance between the impeller and the inlet ho
129. to 200 psi and adjust the air shutter for a clean fire Record the combustion reading from the flue gas analyzer normally 3 5 to 4 5 and less than No 1 smoke Bacharach To adjust the oil pressure regulating valve remove the lockscrew and adjust the 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 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 3 5 to 4 596 with less than No 1 smoke Bacharach 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 6 3 Full Modulation Oil Burner Adjustment The oil burner adjustments consist of the oil metering valve and air damper shutters The oil metering valve position indicated by a scale on the valve will vary the oil pressure to the nozzle Models V13 to V34 use a simplex oil nozzle while models V35 to V168 use a return flow oil nozzle An oil pressure gauge should be 4 18 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMBUSTION installed in the return line to monitor the oil pressure
130. ure and the nozzle s flow rating S SAFETY S SHUT OFF NOZZLE VALVES LIGHT OIL m 2 LEVEL PRESSURE PUMP SOLENOID LOW HIGH MODULATION WITH 2 LEVEL PUMP PRESSURE OIL RETURN OIL INLET The pump is operational but the valves are closed Oil is flowing through an internal relief valve and returning to the supply system Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s low pressure setting Excess oil is flowing through an internal relief valve and returning to the supply system The safety shut off oil valves remain open The pump s solenoid is energized by the auxiliary Switch within the damper actuator as it opens the air damper Oil pressure is then increased based the pumps high pressure setting The burner will then modulate from low to high as described in the combustion air column All valves immediately return to their startup or de energized position The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supply System For pumps without the internal dual pressure solenoid an external pressure relief valve and normally open solenoid valve are used S SAFETY S SHUT OFF PRESSURE pM VALVES RELIEF VALVE N NOZZLE LIGHT ot or VALVE PUMP
131. using set at 3 8 nominal Adjust the inlet cone so it is centered in the inlet of the impeller and tighten the bolts There should be no contact between the inlet cone and the impeller Inserting a bar through the impeller blade and using it as a lever will only damage the blade 5 5 Firing Head Inspection Open side access panels to view the drawer assembly Inspect the lead wire to the ignition electrode It must be firmly attached and the insulation should be clean and free of cracks The oil nozzle should be inspected periodically If fibrous material is discovered in the gas spud ports remove the gas spud and back flush with shop air Further inspection of gas piping and gasket connections must be made to isolate the contaminate source Be sure to orientate the gas spuds in the correct position when reassembling the gas spuds 5 5 1 Drawer Assembly The drawer assembly may be removed for inspection and or service For drawer assembly drawings refer to section 4 4 4 for firetube applications and 4 4 5 for watertube or cast iron applications 1 Shut off the burner position the switch to Off Shut off all electric power to the burner Disconnect the fuel lines from the drawer assembly access cover 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 Reach inside to disconnect the ignition cabl
132. ustment On Off gas burners are typically equipped with a pressure regulator and a solenoid operated diaphragm gas valve to control the on off operation of the burner Adjustments are made by matching the correct fuel air ratios 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 pressure 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 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 3 Turn the burner switch to the ON position 4 Adjust the burner for a smooth ignition of the main flame The bleed valve adjustment controls the opening of the V48 valve When the controller is not calling for heat the coil is de energized The plunger in the 3 way actuator is in the DOWN position so the bleed port is closed and the supply port is open Gas flows into the top part of the valve The gas pressure on top of the diaphragm the weight and the 4 14 IC SA 1511 02 2014 V LNV Series Manual Adjustments INDUSTRIAL COMB
133. w to high rate positions based on the signal from the modulating control and the selection of the low auto Damper returns to its start position based on the 25 second closure speed of the mechanical actuator None Gas Safety shut off valve s are provided to initiate the flow of gas The primary is a diaphragm or motorized type valve which have delayed opening rates to prevent an in rush of gas A butterfly type gas metering valve is linked directly to the damper actuator and provides gas flow metering during the drive to the high position A manually adjusted gas regulator limits maximum firing rate Valves are closed Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting The gas valves remain in their open position The actuator begins it s travel to the high fire position opening the gas metering valve The burner will then modulate from low to high as described in the combustion air column On shut down all gas valves close within 1 second The butterfly valve closes in 25 seconds with the two position actuator None Oil Pressure Atomization Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle The oil pump has a built in solenoid controlled two level pressure regulating system Low and high flow rates are set on the pump based on press
134. y Any warranty adjustments made by the Company shall not extend the initial warranty period set forth above Expenses incurred by Buyer in replacing or repairing or returning the equipment or any part or parts will not be reimbursed by the Company Spare and Replacement Parts Warranty Adjustment The Company sells spare and replacement parts This subparagraph 10 4 is the warranty adjustment for such parts Buyer must make claim of any breach of any spare or replacement parts by written notice to the Company s home office within thirty 80 days of the discovery of any alleged defect for all such parts manufactured by the company The Company agrees at its option to repair or replace BUT NOT INSTALL F O B Company s plant any part or parts or material it manufacture which within one 1 year from the date of shipment shall prove to Company s satisfaction including return to the Company s plant transportation prepaid for inspection if required by the Company to be defective within this part warranty The warranty and warranty period for spare and replacement parts not manufactured by the company purchased by the Company from third party suppliers shall be limited to the warranty and warranty adjustment extended to the Company by the original manufacturer of such parts In no event shall such other manufacturer s warranty create any more IC SA 1511 02 2014 V LNV Series Manual INDUSTRIAL COMBUSTION extensive warranty obligations o
135. y gas valve increasing the flow of gas to the manifold The burner continues to modulate as described under the combustion air heading demand is satisfied until The safety shut off oil valves remain open As the actuator begins it s travel to the firing rate position it is also adjusting the oil metering valve decreasing the amount of oil allowed to return to the pump This in turn is increasing the pressure and volume of oil at the nozzle The burner will continue to modulate as described under the combustion air heading until demand is satisfied Damper returns to its starting position based on the 30 second closure speed of the mechanical actuator SHUT DOWN POST PURGE On shut down all gas valves close within 1 second The butterfly valve closes in 30 seconds with the damper actuator All valves immediately close The metering valve opens to its low fire position in 30 seconds with the damper actuator The oil pump is operating with post purge but oil is flowing through an internal relief valve and returning to the supply system 2 18 IC SA 1511 02 2014 V LNV Series Manual Installation INDUSTRIAL COMBUSTION FULL MODULATION LOW or 60 DAMPER PURGE Combustion Air Gas Oil On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut off valve

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