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IC-SA-790 D-LND Series Manual 10-2010

1. Blast Tube Assembly Ouantity SC Part No Description 42 54 63 84 105 145 175 210 252 300 315 336 0 1 8 1029 Bracket 23 Support Standard 2 2 2 2 2 2 Panel 8 1275 Bracket 28 Support Standard 2 2 2 2 2 2 Panel 2 817 829 Switch Pressure Air Oil 4 12 psi 1 1 1 1 3 40 377 Housing Assembly Firing Head 1 1 1 40 378 Housing Assembly Firing Head 1 1 40 400 Housing Assembly Firing Head 1 40 381 Housing Assembly Firing Head 1 40 382 Housing Assembly Firing Head 1 40 380 Housing Assembly Firing Head 1 1 1 40 410 Housing Assembly Firing Head 1 4 8 1025 Bracket Safety Interlock Switch 1 1 1 1 1 1 1 1 1 1 1 1 5 836 301 Switch Safety Interlock 1 1 1 1 1 1 1 1 1 1 1 1 6 32 1127 Seal varies 7 19 485 Cover Firing Head Access 1 1 1 19 486 Cover Firing Head Access 1 1 19 487 Cover Firing Head Access 1 19 489 Cover Firing Head Access 1 1 19 488 Cover Firing Head Access 1 1 1 1 8 31 36 Glass Flame Sight 1 1 1 1 1 1 1 1 1 1 1 1 9 869 184 Nut Sight Glass 1 1 1 1 1 1 1 1 1 1 1 1 10 85 885 Support Assembly Burner 1 1 1 1 1 85 886 Support Assembly Burner 1 1 85 887 Support Assembly Burner 1 1 1 1 1 DLG IC 790 revised 2010 9 5 D LND Series Manual INDUSTRIAL COMBUSTION 9 4 2 Blast Tube Assembly D378 420 9 6 IC 790 revised 2010 D LND Series Manual 9 4 Parts List
2. Compressor Set Assemblies Ouantity Item Part No Description 378 420 No 1 35 440 Radiator Guard Assembly 1 1 2 17 234 Radiator Assembly 1 1 3 848 514 Electrical J unction Box 1 1 4 39 446 Air Flow Duct Assembly 1 1 5 35 439 Belt Guard Weldment 1 1 6 951 174 Fan Blade 1 1 7 74 516 Fan Mounting Shaft 1 1 8 809 223 V Belt 1 1 9 810 73 Bushing 1 1 10 921 538 Sheave 1 1 11 810 72 Bushing 1 1 12 921 537 Sheave 1 1 13 894 1380 Motor 15 HP 3 PH 208 Volt T 1 894 1381 Motor 15 HP 3 PH 230 460 Volt 1 1 14 59 1284 Motor Mounting Base 1 1 15 3 377 Compressor Base 1 1 16 35 438 Compressor Shaft End Guard 1 1 17 923 112 Air Filter I 1 18 940 1281 1 1 2 NPT Horizontal Check Valve 1 1 19 843 106 Oil Filter 1 1 20 10 315 Oil Filter Mounting Bushing 1 1 21 940 1279 1 NPT Horizontal Check Valve 1 1 22 195 261 Oil Air Tank Assembly 1 1 23 851 180 Sight Gauge 1 1 24 832 925 Low Lube Oil Sensor optional 1 1 25 941 127 1 1 2 NPT Shutoff Valve 1 1 26 505 322 Air Compressor 1 1 27 940 654 1 4 Oil Valve 2 Way N C 1 1 28 900 676 Filter Compressor Pipe 1 1 29 171 104 Filter Basket 1 1 30 13 251 1 1 2 NPT Pipe Cap 1 1 31 19 532 Cover Belt Guard 1 1 32 19 533 Cover Belt Guard 1 1 33 8 1903 Bracket Tank Mounting 2 2 34 850 3 Gauge Pressure 0 60 PSI 2 5 Dial 1 4 NPT 1 1 35 118 832 Nameplate 1 1 IC
3. Modulation Ouantity Item Part No Description 315 336 378 420 No 1 894 1346 Motor Modutrol 24V 30 Sec 1 1 1 1 3 807 341 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 4 10 322 Bushing Mod Motor Control Arm 12 LG 1 1 1 1 5 2 259 Arm Linkage 3 4 Shaft 6 Holes 2 2 2 2 6 82 153 Spring Roller Guide Cam 1 1 1 1 7 36 111 Guiide Cam Spring 16 16 16 16 8 71 24 Screw Spring Fastener 2 2 9 860 301 Screw Locking Set Kit 16 per kit 1 10 860 299 Screw Set 10 32 X1 LG Half Dog Point 16 16 16 16 11 313 14 Cam Assembly Left Hand 1 1 1 1 313 15 Cam Assembly Right Hand 2 2 2 2 12 476 84 Linkage Cam Follower Assembly Gas 1 1 1 1 476 82 Linkage Cam Follower Assembly Oil 1 1 1 1 13 2 13 Arm Linkage 5 16 Shaft 17 Holes 1 1 1 1 14 69 303 Roller Guide Assembly 2 2 2 2 15 8 1356 Bracket Linkage Arm Mounting 2 2 2 2 16 74 504 Shaft Linkage Arm Mounting Single Spring Gas 1 1 1 1 74 506 Shaft Linkage Arm Mounting Double Spring Oil 1 1 1 1 17 807 339 Bearing Nylon 3 8 1 D 2 2 2 2 18 82 140 Spring Cam Asembly Return Gas 1 1 1 1 82 155 Spring Cam Assembly Return Oil 1 1 1 1 19 10 343 Bushing Mod Motor Control Arm 34 11 16 LG 1 1 1 1 20 2 184 Arm Linkage 3 4 Shaft X 3 Slot 1 1 9 54 IC 790 revised 2010 D LND Series Manual
4. Oil Metering Assembly Ouantity Item Part No Description 378 420 No 1 894 928 Motor 1 HP 1 1 2 921 526 Sheave BC38 5 8 Bore 1 1 3 8 1633 Bracket Assembly Metering Head 1 1 4 29 1149 Flange Oil Metering Adaptor 1 1 5 695 112 Metering Head Assembly Oil 300L 1 1 6 282 13 Stop Assembly Override E Style Metering Head 1 1 7 476 53 Linkage Assembly Limiting Arm 9 Holes 5 16 1 1 8 35 437 Guard Metering Head and Motor Belt 1 1 9 809 222 Belt V 1 1 10 810 71 Bushing 1 1 11 921 536 Sheave 6 1 2 O D X6 P D X 1 9 16 I D T 1 12 19 531 Cover Motor Sheave 1 1 IC 790 revised 2010 9 47 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 23 Modulation Standard Standard Modulation Ouantity Item Part No Description 42 54 63 84 105 145 175 No 1 894 1345 Motor Modulation 120V 35 Sec 1 1 1 1 1 894 1346 Motor Modulation 24V 30 Sec 1 1 2 18 149 Collar Steel 1 1 1 1 1 3 807 335 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 1 807 341 Bearing Flanged 2 PT 3 4 Shaft 1 1 4 10 309 Bushing Mod Motor Control Arm 9 1 2 LG 1 1 1 1 1 1 1 5 2 184 Arm Linkage 3 4 Shaft X 3 Slot 2 2 2 2 2 2 2 6 2 141 Arm Linkage 3 4 Shaft 7 Holes 1 1 1 1 1 1 1 Standard
5. Burner Size Max Burner Gas Input MBTU hr 60hz 50hz 2 S or P 4 200 3 360 4 S or P 5 400 4 200 3 S or P 6 300 5 250 4 S or P 8 400 6 300 105 S or P 10 500 8 400 145 S or P 14 500 10 500 175 S or P 17 500 14 700 210 S or P 21 000 16 800 252 S or P 25 200 21 000 300 S or P 30 000 25 200 315 P 31 500 30 000 336 P 33 600 31 500 378 P 37 800 33 600 420 P 42 000 37 800 Gas input based on natural gass at 1 000 Btu cu ft and 0 60 specific gravity INDUSTRIAL COMBUSTION Burner Size Max Burner Oil Input U S G P H 60hz 50hz 42 S or P 30 24 54 S or P 39 30 63 S or P 47 38 84 S or P 60 53 105 S or P 75 60 145 S or P 107 90 175 S or P 125 105 210 S or P 150 120 252 S or P 180 150 300 S or P 215 180 315 P 225 215 336 P 240 225 378 P 270 240 420 P 300 270 Oil input based on No 2 oil at 140 000 Btu gal INDUSTRIAL COMBUSTION INDUSTRIAL COMBUSTION D LND Series Table of Contents CHAPTER 1 CHAPTER 2 Introduction 1 1 1 1 Overview 1 1 1 2 Description 1 1 1 3 Operating Controls 1 2 1 4 Flame Safeguard Controls 1 2 1 5 Combustion Air Handling System 1 3 1 6 Firing Rate Controls 1 3 1 7 FiringHead 1 4 1 8 Oil System Air Atomizing 1 5 1 8 1 3 Way Solenoid Valve 1 5 1 8 2 Nozz
6. Model Standards Fuel Air Atomization DG Gas DL 2 Oil DLG 2 Oil and Gas DM 2 5 Oil DMG 2 5 Oil and Gas DE 2 6 Oil DEG 2 6 Oil and Gas S Models for up to 1 5 W C furnace pressure P Models for up to 4 0 W C furnace pressure Example The model number on the nameplate is DLG 252 No 2 oil and gas burner with input rated at 25 200 MBtu per hour against furnace pressures up to 4 W C at 60hz NOTE Firing at higher furnace pressures de rates the burner by approximately 5 per one half inch of additional pressure Consult with the factory The installation of a burner shall be in accordance with the regulations of authorities having jurisdic tion The equipment must be installed in accordance with applicable local state or provincial instal lation requirements including the National Electrical Code NEC and Associated Insurance Underwriters Where applicable the Canadian Gas Association CGA B149 and Canadian Standard Association CSA B140 and B139 for oil burners codes shall prevail Oll and gas burning equip INDUSTRIAL COMBUSTION ment shall be connected to flues having sufficient draft at all times to assure safe and proper opera tion of the burner The D Series burners are designed to burn either gas or light oil No 1 or 2 as defined by ASTM D396 1978 specifications and heavy oils Do not use gasoline crankcase oil or any oil containing gasoline
7. 2 PA 02227 2722 AL RE Z 4 j0 05050606060506060606050606060606060606060 606060606060 60606 PACK WITH PLASTIC REFRACTORY A kd 0o0oo000000000000000000000000000000000900000000000909000 BOILER FRONT PLATE AS b SSSR RNR 0 0 0000 ID KAISER MONO T 9 AIR SET OR 1 lt bd 16060606060 0609060606060606060606060606060606 06006 AT EE EOUAL RAM FROM FRONT TO REAR Dd CC OC X OC X X C OX C XC gt C C OC OC OC OC OC OX OC C CO 245 CX 0 X 9C C 9C XC OC gt C C gt gt A OCOCO VA LoC OX 0 9 6 ri a 0 0 050605050606050606060905060606050 Ce PLI K 4 D i KRSS ORR KRRKRRKRRRRKRK AY OSS SOOS KOKS SSSS WRAP DRY OVEN EE gt WITH KAO WOOL Seng COAT BOTH SIDES WITH TROWLEZE COAT OUTER CIRCUMFERENCE OF DRY OVEN WITH TROWLEZE DRY OVEN SUPPLIED WITH BURNER STEEL WRAPPER ON CONE NOTES 1 GASKET SUPPLIED WITH BURNER 1 LAY THE DRY OVEN ON THE FLOOR WITH THE STUDS UP CAREFULLY PRESS THE GASKET OVER THE STUDS 2 LIFT THE DRY OVEN ONTO THE BURNER FLANGE AND GENTLY TIGHTEN THE BOLTS 3 MAKE SURE THE DRY OVEN IS CENTERED ON THE BURNER FLANGE SO THE SPACE IS EQUAL ALL AROUND THE BURNER BLAST TUBE 4 MAKE SURE THAT NONE OF THE GASKET IS PROTRUDING INTO THE AIR STREAM TIGHTEN THE DRY OVEN NUTS S WRAP THE DRY OVEN WITH TROWLEZE COATED KAO WOOL AND LIFT THE BURNER ONTO THE BURNER STUDS AND BOLT SECURELY IN PLACE 6 FINISH REFRACTORY WORK INSIDE FURNACE
8. VES OIL METERING GAUGE VACUUM 2 PUMP SUPPLIED GAUGE CATE WITH BURNER GATE VALVE CH CHECK CIRCULATING PUMP PIPING BY OTHERS PIPING BY NO 4 amp 5 OIL RECOMMENDED PIPE SIZE DM LNDM 252 300 315 336 378 420 DM LNDM 252 300 315 336 378 420 THIS PIPING LAYOUT IS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 12 Recommended Pipe Size 2 16 IC 790 revised 2010 D LND Series Manual 2 13 Installation Checklist INDUSTRIAL COMBUSTION BACK PRESSURE VALVE SET AT 10 15 PSI m ig GATE VALVE cd TO DRAWER CHECK ASSEMBLY VALVE lo am um sae sea sie sts aaa AIR PURGE SOLENOID VALVE OIL PREHEATER NOZZLE LINE CHECK SIZED TO FLOW PURGE VALVE d OPTIONAL gt 2 WAY VALVE VALVE 52 ON BURNER i 3 WAY 1 co 1 ALV VALVE 1 ED a ep BURNER DE age es e V puo THERMOMETERS i SWITCHES AUXILIA TRIM LJ HEATER i REQUIRED IF PUMP DOES NOT 1 HAVE AN INTERNAL RELIEF ree ta i RELIEF VALVE SET AT 50 PSI NEEDLE eegene d OIL METERING e E VACUUM 2 PUMP SUPPLIED GATE de hi VALVE EN CHECK 3 Wi VALVE E gt E r1 9 co z VALVE 3 e 5 A ng z TRAINER Pol VALVE STRAINER gt E GATE D u 2 VALVE MN el COLD OIL START le HOT
9. IC 790 revised 2010 9 43 D LND Series Manual INDUSTRIAL COMBUSTION Parts Lists and Drawings Oil Metering Assemblies Ouantity Description 42 54 63 84 105 145 175 210 252 300 315 336 0 1 894 934 Motor 1 2 HP 1 1 1 1 1 1 1 894 936 3 4 1 1 1 1 1 2 40 296 Housing Mounting Oil Pump to 1 1 1 1 1 1 1 1 1 1 1 1 Motor 3 19 342 Cover Drive Coupling Access 2 2 2 2 2 2 2 2 2 2 2 2 4 819 114 Coupling Drive 9 16 X 5 8 Bore 1 1 1 1 819 105 Coupling Drive 5 8 X 5 8 Bore 1 1 1 1 1 1 1 1 5 695 80 Metering Head Ass y Oil 30L 1 695 70 Metering Head Ass y Oil 40L 1 1 695 71 Metering Head Ass y Oil 60L 1 695 81 Metering Head Ass y Oil 75L 1 695 72 Metering Head Ass y Oil 100L 1 695 82 Metering Head Ass y Oil 125L 1 695 73 Metering Head Ass y 150L 1 695 83 Metering Head Ass y Oil 180L 1 695 74 Metering Head Ass y Oil 200L 1 695 75 Metering Head Ass y Oil 350L 1 1 6 282 13 Stop Ass y Override M etering 1 1 1 1 1 1 1 1 1 1 1 1 Head 7 476 53 Linkage Ass y Limiting Arm 9 1 1 1 1 1 1 1 1 1 1 1 1 Holes 5 16 8 940 1372 Valve Oil Solenoid 1 2 2 Way 1 1 1 1 1 1 N C DL Valve Oil Solenoid 1 2 2 Way 1 1 1 1 1 1 N C DM Valve Oil Solenoid 1 2 2 Way 1 1 1 1 1 1 1 1 1 1 1 1 N C DE 9 940 1348 Valve Oil Solenoid 1
10. Refer to the manufacturer s literature on programming controls and burner wiring diagrams for detailed informa tion 1 m gt N 9 Begin starting sequence with burner switch off and with all manual valves closed Switch main power on 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 Place the gas oil selector switch in position for the fuel to be used 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 When the limit or operating controls open Fuel valves close The main fuel lamp goes off Flame safeguard timer starts The flame safeguard timer and burner motor stop The burner is ready for startup on the next call for heat 3 6 Manual Shutdown Turn the gas oil selector switch OFF The burner shuts down in Automatic Shutdown When the burner motor stops close all manual valves Safety Shutdown If at any time during the operating cycle a flame failure occurs the burner shuts down as in Automatic Shut
11. Bore 1B Groove 1 13 921 527 Sheave 3 15 P D X 7 8 Bore 1B Groove 1 14 810 70 Bushing Split Taper 1 Bore X 1 9 16 Dia 1 1 1 1 1 1 15 74 516 Shaft Cooling Fan Mounting 1 1 1 1 1 1 16 951 174 Fan 3 Blade 12 Dia 5 8 Bore 1 1 1 1 1 1 17 39 446 Shroud Assembly Cooling Fan 1 1 1 1 1 1 18 195 256 Tank Assembly Oil Air 350 Cu In 1 1 1 1 1 1 19 118 747 Nameplate 1 1 1 1 1 1 20 39 443 Shroud Assembly Fan Enclosure 1 1 1 1 1 1 21 17 193 Coil Lube Oil Cooling 1 1 1 1 1 1 22 35 413 Guard Assembly Radiator 1 1 1 1 1 1 23 832 925 Sensor Oil Low Lube optional 1 1 1 1 1 1 IC 790 revised 2010 9 15 D LND Series Manual Parts Lists and Drawings COMBUSTION 9 4 7 Compressor Set D175 336 INDUSTRIAL IC 790 revised 2010 D LND Series Manual 9 16 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Separate Compressor Modules Ouantity Item Part No Description 175 210 252 300 315 336 No 1 940 1205 Valve Check 3 4 Horizontal 2 2 2 2 2 2 2 941 584 Valve Shutoff 1 1 4 NPT Butterball 1 1 1 1 1 1 3 923 112 Filter Air 1 1 1 1 4 894 1302 Motor 5 HP 1 1 894 1309 Motor 7 5 HP 1 1 1 1 5 848 499 Box Electrical W Cover 4 X 4 1 1 1 1 1 1 6 29 841 Flange Compressor Mounting 1 1 1 1 1 1 7 505 153 Compressor Assembly Air 5 Single Sha
12. FULL MODULATION MODELS D LND 42 Q 1 FULL SIZE 1 47 OR LARGER PIPE TO BE RUN FROM THE VENT OPENING TO OUTSIDE OF BUILDING 2 NO TRAPS ALLOWED IN VENT LINE 3 VENT LINE SHALL TERMINATE AWAY FROM ALL DOORS AND WINDOWS 4 PROVISIONS SHALL BE MADE TO PREVENT FOREIGN OBJECTS FROM ENTERING VENT PIPING FIGURE 2 16 Typical UL Gas Piping HIGH GAS LOW GAS PRESSURE PRESSURE SWITCH MAIN GAS SWITCH VALVE W P O C BUTTERFLY SHUTOFF VALVE SHUTOFF COCK COCK TO gt BURNER m GEI BURNER DER d PILOT VALVE REGULATOR TYPICAL UL GAS PIPING OVER 5 000 000 UP TO 12 500 000 BTU FULL MODULATION MODELS D LN 54 TO 105 1 FULL SIZE 1 4 OR LARGER PIPE BE RUN FROM THE VENT OPENING TO OUTSIDE OF BUILDING 2 NO TRAPS ALLOWED IN VENT LINE 3 VENT LINE SHALL TERMINATE AWAY FROM ALL DOORS AND WINDOWS 4 PROVISIONS SHALL BE MADE TO PREVENT FOREIGN OBJECTS FROM ENTERING VENT PIPING THESE PIPING LAYOUTS ARE FOR REFERENCE ONLY AND ARE SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EGUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 17 Typical UL Gas Piping 2 20 IC 790 revised 2010 D LND Series Manual 2 13 Installation Checklist DU STRI AL OMBUSTION LOW GAS PRESSURE HIGH GAS PRESSURE SWITCH TEST TA SHUTOFF COCK BUTTERFLY SHUTOFF VALVE COCK TO BURNER REGU TATOR KZ W P O C TO BURNER PILOT VALV
13. 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 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 IC 790 revised 2010 D LND Series Manual 6 3 Troubleshooting INDUSTRIAL COMBUSTION Problem Solution Pilot Flame But No Main Flame 1 Insufficient pilot flame 2 Gas fired unit a Manual gas cock closed b Main gas valve inoperative c Gas pressure regulator inoperative 3 Limit circuit not completed no voltage at end of limit circuit program relay terminal a Oil supply cut off by obstruction closed valve or loss of suction b Supply pump inoperative c No fuel d Main oil valve inoperative e Check oil nozzle gun and lines 4 Flame detector defective sight tube obstructed or lens dirty 5 Insufficient or no voltage at main fuel valve circuit terminal Problem Solution Burner Stays in Low Fire 1 Pressure or temperature above modulating control setting Manual automatic switch in wrong position Inoperative modulating motor Defective modulatin
14. s flame safeguard manual A Warning Read the flame safeguard manual and fully understand its contents before attempting to operate this eguipment Fail ure to follow this instruction may result in serious personal injury or death 1 2 IC 790 revised 2010 D LND Series Manual 1 5 Combustion Air Handling System INDUSTRIAL COMBUSTION 1 5 Combustion Air Handling System The combustion air handling system consists of three major components Component Details Damper Assembly A rotary damper regulates the combustion air volume and is positioned by a modulating motor The damper is normally almost closed in the low fire position and opens as the burner drives toward a high fire position Motor Driven Impeller The diameter of the impeller determines available air pressure and the width determines air capacity in cubic feet per minute Alternate motor impeller combinations are available for 50 cycle or 60 cycle power and for firing against either moderate or high furnace pressure At altitudes up to 2 000 ft above sea level model S impellers are recommended for up to 1 5 W C furnace pressure Model P impellers are recommended for fur nace pressures from 1 5 to 4 0 W C For higher altitudes and higher fur nace pressure motor and impeller combinations are determined at the factory Stator Cone The stator cone in the air housing transforms the rotating air velocity pres
15. 1 5 D LND Series Manual Introduction INDUSTRIAL COMBUSTION The nozzle body has inlet ports for air and oil lines Metered fuel oil enters the nozzle body and flows through a tube to the swirler Oil is forced from the core of the swirler to the side ports where it meets with atomizing air Atomizing air enters and passes through the nozzle body to grooves in the swirler where it mixes with fuel oil Air oil passes through grooves and out of the nozzle orifice in a cone of atomized oil Proper velocity and angle of the fine spray ensures good mixing with the combustion air providing quiet starts and excellent combustion effi ciency During pre and post purge the nozzle tip is purged with air This prevents afterdrip or baked on residue Compression Spring Nozzle Tip Nozzle Body Swirler Atomizing Air FIGURE 1 4 Nozzle Assembly 1 8 3 Burner Mounted Trim Heater This provides heat for No 4 5 and 6 fuel oil and is located between the metering pump and the 3 way valve This heater should not be used as a continuous run line heater The heater has an adjustable thermostat and a cold oil lockout switch which prevents the burner from starting until proper atomizing temperature is attained 1 8 4 Oil Strainer Prevents foreign matter from entering the burner oil system 1 8 5 Atomizing Air Proving Switch Pressure actuated switch contacts close when sufficient atomizing air pressure is present The oil val
16. 5 11 6 Compressor Oil Filter Lube Oil Strainer 5 7 5 11 7 Oil Strainers 5 7 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 Impeller and Stator Cone 5 2 5 4 Firing Head Inspection 5 2 5 5 Pilot and Ignition Electrode 5 4 5 6 Flame Scanner 5 4 5 7 Oil Nozzle 5 4 5 8 Diffuser 5 6 5 9 Firing Rate Controls 5 6 5 10 Burner Mounting Inspection 5 6 iv IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 6 CHAPTER 7 5 11 Fuel Oil System 5 7 5 11 1 Fuel Oil Circulating Pump 5 7 5 11 2 Air Oil Metering Pump 5 7 5 11 3 Primary Air Pump or Compressor 5 8 5 11 4 AirCleaner 5 8 5 11 5 Air Oil Tank 5 8 5 11 6 Oil Level Sight Gauge 5 8 5 11 7 Compressor Oil Filter Lube Oil Strainer 5 8 5 11 8 Nozzle Line Heater 5 9 5 11 9 Oil Strainers 5 9 5 12 Gas System 5 9 5 12 1 Motorized Main Gas Valves 5 9 5 12 2 Solenoid Valves 5 9 5 13 Electrical System 5 10 5 13 1 Electric Motors 5 1 0 5 14 Extended Shutdown 5 10 5 15 Maintenance Flow Chart Recommended Test Schedule 5 11 Troubleshooting 6 1 6 1 Awareness 6 1 6 2 Emergency Shutdown 6 2 6 3 Troubleshooting 6 3 Accessories 7 1 7 1 Overview 7 1 7 2 Steam Atomizing System 7 1 7 3 Air Purge System optional 7 2 7 4 Plant Air System 7 2 IC
17. Atomizing air is regulated by an adjusting valve in the return air line on integral metering units or in the air inlet on air compressor module burners 1 8 10 Oil Metering Fuel oil under nominal pressure in the circulating loop flows to the adjustable positive displacement volumetric metering unit Oil metering is accomplished by changing the piston stroke by means of an eccentric shaft and pin assembly The pistons reciprocate in a rotor assembly turning in a hardened steel sleeve having oil inlet and dis charge slots During each revolution the pistons go through the following cycle 1 Inlet Cycle The piston is at the bottom dead center position At this position the cavity between the top of the piston and the outside diameter of the rotor fills with oil 2 Discharge Cycle 180 from inlet cycle The piston is at the top dead center position At this position the oil is forced out of the discharge port to the nozzle The piston stroke length is determined by the position of the eccentric shaft and plate The piston adjustment plate is positioned by an adjustable eccentric shaft The eccentric shaft is positioned by the modulator through adjustable linkage Counterclockwise rotation of the eccentric shaft increases the piston stroke more oil delivered to the nozzle clockwise rotation decreases the amount of oil delivered When the eccentric shaft is stationary at any position the stroke of the pistons remains constant delivering a
18. Back Pressure Valve A back pressure valve similar to Watson McDaniel type R needs to be installed on the return line as shown in Figure 2 6 This valve must be installed in an upright vertical position Before installing the valve be sure to 2 8 IC 790 revised 2010 D LND Series Manual 2 12 Gas Piping INDUSTRIAL COMBUSTION blow outthe pipe line removing all dirt pipe scale and sediment This type of valve is actuated by the system pressure which enters the body beneath the main valve Valve loading is provided by a spring that can be adjusted to the desired set pressure To adjust the set pressure remove the top cap loosen the brass locknut and adjust the pressure with the steel setscrew By increasing the compression on the spring screwing down the screw you increase the set pressure within the limits of the spring range Reversing the setscrew lowers the set pressure Adjust to 10 15 PSI for No 2 oil systems and 15 20 PSI for heavy oils When the desired pressure is reached tighten the locknut and replace the to cap and gasket 2 12 Gas Piping Refer to Figures 2 16 to 2 19 for typical gas piping schematics Gas service and house piping must supply the quantity of gas demanded by the unit at the pressure required at the burner gas train inlet All piping must be in strict accordance with applicable codes ordinances and regula tions of the supplying utility In the absence of other codes piping shoul
19. PIPING BY TANK NO 6 OIL RECOMMENDED PIPE SIZE E DE LNDE 252 300 315 336 378 420 DE LNDE 252 300 315 336 378 420 THIS PIPING LAYOUT IS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 14 Recommended Pipe Size 2 18 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION Installation Checklist 2 13 W30n8 HUM CD 14475 SINING S IA Nd Wel W31SAS TIO NOLIYTIVISNISUINUNA 3141 LY 5u3H1O LE nau SUINANAOLENNHA Ei VOA W31SAS ONLY DON VIVA uvo 3902 340 NHS WA AW 1 b ven a T 3002 HO IHS DAVI IESI di Wunn SEI JANA AYAZ TIZZON OL Ait X200 4340 Up 39005 30055344 MO41nWs 409 Sin ECH 200 Vi NO amv c SNA AWE UIS WOOD 4 OANHS DNS ESA 53100 v 340 9384 IS 40E 1V 135 m d 15V And JOVI weu Dueno EMEND de Weck vi LOH 4 00201 4144015 110 1 V3H AL 1801175 LIV 3H3H4 JH 1 IY M LOH VOWS 01 DBL THNOUNNISWO 2 NO 58531 X200 130 LHS 3 390 vo Wnro v LEL vis 3 OO ANOVA JL 2 19 FIGURE 2 15 Multiple Boilers Installation Heavy Oil IC 790 revised 2010 D LND Series Manual q M DUSTRIAL Introduction COMBUSTION HIGH GAS PRESSURE SWITCH BUTTERFLY SHUTOFF VALVE PILOT REGULATOR VALVE TYPICAL UL GAS PIPING OVER 2 500 000 UP TO 5 000 000 BTU
20. Stator 1 13 40 246 Housing Assembly Fan 1 1 1 40 250 Housing Assembly Fan 1 1 40 247 Housing Assembly Fan 1 40 268 Housing Assembly Fan 1 14 32 1060 Gasket Fan Housing Seal 1 1 1 1 1 1 1 DE DEG 3 HP DE DEG 42 54 amp 63 IC 790 revised 2010 9 9 D LND Series Manual INDUSTRIAL COMBUSTION 9 4 4 Blower Housing Assembly D210 336 9 10 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Blower Housing Assemblies Ouantity Item Part No Description 210 252 300 315 336 No 1 894 1249 Motor 20 HP S 894 1251 Motor 25 HP P S 894 1255 Motor 40 HP p S amp P 894 1351 Motor 60 HP 1 1 2 515 16 Seal 1 1 1 3 39 452 Shroud Assembly Air Hood 1 1 1 1 1 4 85 812 Support Motor and Air Damper 9 S 85 813 Support Motor and Air Damper P 1 1 1 5 91 Spacer varies 6 192 308 Impeller Assembly 21 1 2 O D X 2 1 2 Wide X 1 5 8 Shaft S 192 299 Impeller Assembly 23 O D X 2 11 32 Wide X 1 5 8 Shaft P S 192 307 Impeller Assembly 23 1 2 O D X 2 9 32 Wide X 1 5 8 Shaft P 192 321 Impeller Assembly 25 1 2 O D X 2 5 8 Wide X 1 5 8 Shaft S amp P 192 306 Impeller Assembly 25 1 2 O D X 3 9 32 Wide X 1 5 8 Shaft 1 1 7 869 185 Nut Hex Lock 1 3 8 12 UNF 1 1 1 1 1 8 152 17 Pad Blow
21. ei Em pe reen d N QUOUOQUOUQUQUU A A 4 KAAAAAAAAAAAAA A AA AAAA AAAAN Y G i d d d xX xy A Y d d Y 4 4 t A A A A A Y 7 Y V h x A A d d d 4 FIGURE 2 5 Separate Compressor Module 2 6 Typical Oil Supply Loop Refer to Figure 2 6 Continuous oil circulation must be supplied to the burner at a rate of 5096 greater than the high fire burning rate The oil circulating pump should be located as close as possible to the storage tank to keep suction lines short and minimize suction loss Pipe line sizes indicated on the following oil piping schematics are of ample size to reduce pressure losses If heating of the fuel oil is required the lines must be large enough to prevent restriction of flow through any cold spots in the system Note that the supply line is approximately 20 inches or higher above the burner metering pump inlet to help eliminate air problems Above that is an adjust able spring loaded back pressure valve that sets approximately 10 to 15 PSI on the circulating loop The return line to the tank is connected at the discharge port of the back pressure valve Since air rises to the highest point it will rise from
22. mi Le p ION Introduction 2 22 IC 790 revised 2010 D LND 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 cer tain these connections are tight The operator should become familiar with the burner boiler controls and com ponents Adjustment procedures given in Chapter 4 should be reviewed prior to firing The wiring diagram should also be studied along with the operating sequence of the burner programmer Read and understand starting instructions before attempting to operate the burner Before attempting to start the burner the following checks must be made Component Description Burner Check the electrical power supply to the burner in accordance with the nameplate voltage on all motors and the control circuit Check the direction or rotation of the motors Open the housing to check the electrode setting refer to Chapter 5 Check the gas pilot pressure at the pilot gas regulator The normal setting is 3 to 5 W C For protection in shipment the flame safeguard control chassis is shipped unmounted Check all screw connections before attaching the flame safeguard chassis to the base Screws must be secure to assure low resistance connections The relay chassis is mounted on the sub base with a screw which when tight
23. 160 260 Deg 1 1 1 1 7 937 163 Gauge Temperature 50 300 Deg 1 2 NPT 1 1 1 1 9 40 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 20 Oil Metering Assembly DL DLG DM DMG42 145 lt e SE lt KM WT TS SS AASA SI AAS SSW N SW 8 gt IC 790 revised 2010 9 41 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION Oil Metering Assemblies Ouantity Item Part No Description 42 54 63 84 105 145 No 1 894 1289 Motor 1 HP Models DL DLG 1 1 1 1 894 1295 Motor 2 HP Models DL DLG 1 1 894 1289 Motor 1 HP Models DM DMG 1 1 894 1295 Motor 2 HP Models DM DMG 1 1 1 1 2 40 296 Housing Mounting Oil Pump to Motor 1 1 1 1 1 1 3 19 342 Cover Drive Coupling Access 2 2 2 2 2 2 4 819 114 Coupling Drive Models DL DLG 1 1 1 1 819 105 Coupling Drive Models DL DLG 1 1 819 114 Coupling Drive Models DM DMG 1 1 819 105 Coupling Drive Models DM DMG 1 1 1 1 5 923 115 Filter Air 1 1 1 1 1 1 6 695 90 Meter amp Compressor Assembly Oil Air 5 4 Models DL DLG 1 695 92 Meter amp Compressor Assembly Oil Air 6 4 Models DL DLG 1 695 94 Meter amp Compressor Assembly Oil Air 7 4 Models DL DLG 1 695 100 Meter amp Compressor Assembly Oil
24. 4 18 Oil Air Tank DL DM42 145 9 38 9 4 19 Oil Heater D42 420 9 39 9 4 20 Oil Metering Assembly DL DLG DM DMG42 145 9 41 9 4 21 Oil Metering Assembly DL DLG DM DMG175 420 amp DE DEG42 420 9 43 9 4 22 Oil Metering Assembly 0378 420 9 46 9 4 23 Modulation Standard 9 48 9 4 24 Modulation Standard Low NOx or Left Hand Gas 9 49 9 4 25 Modulation Cam Trim 9 50 9 4 26 Modulation Cam Trim Low NOx or Left Hand Gas 9 52 STARTUP SERVICE REPORT WARRANTY POLICY IC 790 revised 2010 D LND Series Manual vii INDUSTRIAL COMBUSTION viii IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER Introduction 1 1 Overview Industrial Combustion D Series burners are assembled wired and tested at the factory They are listed by the Underwriters Laboratory CSD 1 NFPA 85 I R I F M including the National electrical Code NEC and associ ated insurance underwriters Where applicable the Canadian Gas Association CGA B149 and Canadian Stan dards Association CSA B140 codes shall prevail Other regulatory agency control options are available N Caution Only factory authorized burner service personnel should start up adjust or service this equipment The operator must be familiar with the individual functioning of all controls to understand the operations and procedures described in the manual Identify and locate each i
25. 790 revised 2010 D LND Series Manual 9 19 Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 9 Control Package Fireye 9 20 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Fireye Control Package Ouantity d Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 833 1340 Module Display W Controller Mounting Cable 1 1 1 1 1 1 1 1 1 1 2 832 915 Program Module EP160 60 Sec Pre Purge 1 1 1 1 1 1 1 1 1 1 832 916 Program Module EP360 60 Sec Pre Purge 1 1 1 1 1 1 1 1 1 1 832 917 Program Module EP390 90 Sec Pre Purge 1 1 1 1 1 1 1 1 1 1 3 832 914 Amplifier Signal Autochecking Infrared 1 1 1 1 1 1 1 1 1 1 832 918 Amplifier Ultra Violet 1 1 1 1 1 1 1 1 1 1 4 833 1018 Base Controller 1 1 1 1 1 1 1 1 1 1 5 833 1337 Chassis E110 1 1 1 1 1 1 1 1 1 1 Fireye Control Package Ouantity Item Part No Description 315 336 378 420 No 1 833 1340 Module Display W Controller Mounting Cable 1 1 1 1 2 832 915 Program Module EP160 60 Sec Pre Purge 1 1 1 1 832 916 Program Module EP360 60 Sec Pre Purge 1 1 1 1 832 917 Program Module EP390 90 Sec Pre Purge 1 1 1 1 3 832 914 Amplifier Signal Autochecking Infrared 1 1 1 1 832 918 Amplifier Ultra Violet 1 1 1 1 4 833 1018 Base Controller 1 1 1 1 5 83
26. 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 8 CHAPTER 9 Flue Gas Recirculation 8 1 8 1 LN Model Designations Sizes and Inputs 8 1 8 2 Description 8 3 8 3 FGR Shutoff Valve 8 4 8 4 FGR Control Valve 8 5 8 5 Air FGR Damper Assembly 8 5 8 6 Blast Tube Temperature Interlock optional 8 7 8 7 Stack Temperature Interlock optional 8 7 8 8 20 PPM Design 8 7 Parts Lists and Drawings 9 1 9 1 Instructions 9 1 9 2 Parts Shipping Policy 9 1 9 3 Return Goods Procedures Credit or Replacement Parts 9 2 9 4 Parts Lists and Drawings 9 4 9 4 2 Blast Tube Assembly D42 336 9 4 9 4 2 Blast Tube Assembly 0378 420 9 6 9 4 3 Blower Housing Assembly D42 175 9 8 9 4 4 Blower Housing Assembly 0210 336 9 10 9 4 5 Blower Housing Assembly D378 420 9 12 9 4 6 Compressor Set D42 145 9 14 9 4 7 Compressor Set 0175 336 9 16 9 4 8 Compressor Set D378 420 9 18 9 4 9 Control Package Fireye 9 20 9 4 10 Control Package Honeywell 9 22 9 4 11 Damper Assembly D42 420 9 24 9 4 12 Damper Assembly LND42 420 9 26 9 4 13 Drawer Assembly D42 63 9 28 9 4 14 Drawer Assembly 084 145 9 30 9 4 15 Drawer Assembly D175 336 9 32 vi IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION 9 4 16 Drawer Assembly D378 420 9 34 9 4 17 Firing Head Assembly D42 420 9 36 9
27. Ignition Cable Straight 1 1 17 873 93 Electrode Assembly Ignition W Bushing 1 1 18 275 439 Diffuser Assembly Air Standard All Models 1 1 IC 790 revised 2010 9 35 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 17 Firing Head Assembly D42 420 9 36 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Firing Head Assemblies Ouantity d Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 257 156 Manifold Assembly Gas Firing Head 1 257 157 Manifold Assembly Gas Firing Head 1 1 257 147 Manifold Assembly Gas Firing Head 1 257 148 Manifold Assembly Gas Firing Head 1 257 149 Manifold Assembly Gas Firing Head 1 257 153 Manifold Assembly Gas Firing Head 1 1 257 154 Manifold Assembly Gas Firing Head 1 1 2 32 1095 Gasket Mounting Dry Oven 1 1 1 32 1096 Gasket Mounting Dry Oven 1 1 32 1097 Gasket Mounting Dry Oven 1 32 1098 Gasket Mounting Dry Oven 1 1 32 1099 Gasket Mounting Dry Oven 1 1 3 279 58 Dry Oven Assembly 1 1 1 279 60 Dry Oven Assembly 1 1 279 59 Dry Oven Assembly 1 279 76 Dry Oven Assembly 1 1 279 77 Dry Oven Assembly 1 1 4 42 52 Spud Gas Orifice Protection 312 O D 3 3 3 3 3 4 4 5 5 5 5 940
28. LN Model Designations Sizes and Inputs Model designations are based on the type of fuel s to be fired and the amount of furnace pressure to overcome Burner size is based on firing rate maximum input in Btu hr Models Standard Fuel Air Atomization LNDG Gas LNDLG 2 Oil and Gas Two designs of low NOx burners are available One is for less than 30 ppm NOx 3 and the other for less than 20 ppm 3 O when firing natural gas For example if the model number on the nameplate is LNDLG 252P 30 it indicates a No 2 oil and gas burner with input rated at 21 000 MBtu per hour and NOx performance of less than 30 ppm LNDLG 252P 20 indicates a gas and oil burner with input rated at 16 800 MBtu per hour and NOx perfor mance of less than 20 ppm 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 Associate Insurance Underwriters 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 IC 790 revised 2010 8 1 D LND Series Manual Flue Gas Recirculation INDUSTRIAL COMBUSTION Burner Size Max Burner Gas Input MBTU hr 30 ppm lt 20 ppm
29. Modulation Quantity ah Part No Description 210 252 300 315 336 378 420 0 1 894 1346 Motor Modulation 24V 30 Sec 1 1 1 1 1 1 1 3 807 341 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 1 1 1 4 10 309 Bushing Mod Motor Control Arm 9 1 2 LG 1 1 1 1 1 1 1 2 141 Arm Linkage 3 4 Shaft 7 Holes 2 2 2 2 2 2 2 8 2 184 Arm Linkage 3 4 Shaft X 3 Slot 1 1 I 1 1 1 1 9 2 259 Arm Linkage 3 4 Shaft 6 Holes 1 1 1 1 1 1 1 9 48 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings C DUSTRIAL OMBUSTION 9 4 24 Modulation Standard Low NOx or Left Hand Gas LEFT HAND GAS BUTTERFLY ONLY LEFTHAND GAS BUTTERFLY ONLY Standard Modulation Ouantity Part No Description 42 54 63 84 105 145 175 0 1 894 1345 Motor Modulation 120V 35 Sec 1 1 1 1 1 894 1346 Motor Modulation 24V 30 Sec 1 1 2 18 149 Collar Steel 1 1 T 1 1 3 807 335 Bearing Flanged 2 PT 3 4 Shaft 2 807 341 Bearing Flanged 2 PT 3 4 Shaft 2 2 4 10 322 Bushing Mod Motor Control Arm 12 LG 1 1 1 1 1 1 1 5 2 184 Arm Linkage 3 4 Shaft X 3 Slot 2 2 2 2 2 2 2 6 2 141 Arm Linkage 3 4 Shaft 7 Holes 2 2 2 2 2 2 2 7 10 307 Bushing Mod Motor Control Arm 22 LG 1 1 1 1 1 1 1 Standard Modulation Quantity eg Part No Description 210 252 300 315 336 378 420 0 1 894 1346 Motor
30. Seguence 3 4 3 5 Automatic Shutdown 3 5 3 6 Manual Shutdown 3 5 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 6 3 9 Normal Operation 3 7 3 10 Shutdown 3 7 Adjustments 4 1 4 1 Overview 41 4 2 Combustion Adjustment on Gas and Oil 4 1 4 2 1 Stack Temperature 4 1 4 2 2 Smoke Measurement 4 2 4 2 3 Gas Adjustments 4 2 4 2 4 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 2 4 4 Gas System 43 4 4 1 Gas Pressure 4 3 4 4 2 Gas Flow 4 3 4 4 3 Gas Pilot Flame Adjustment 4 3 4 4 4 Main Gas Pressure Regulator 4 3 4 4 5 Low Gas Pressure Switch 4 3 4 4 6 High Gas Pressure Switch 4 4 4 4 7 Gas Combustion Adjustment 4 4 4 4 8 Secondary Valve Adjustment Gas Models D 378 amp 420 4 4 4 4 9 Secondary Valve Adjustment Dual Manifold 4 5 IC 790 revised 2010 D LND Series Manual iii INDUSTRIAL COMBUSTION 4 5 Oil System 4 5 4 5 1 Oil Metering System 4 5 4 5 2 Atomizing Air Pressure 4 6 4 5 3 Atomizing Air Proving Switch 4 6 4 5 4 Low Oil Pressure Switch 4 6 4 5 5 High Oil Temperature Switch 4 6 4 5 6 Nozzle Line Heater 4 7 4 6 Linkage Modulating Motor 4 7 4 7 Cam Trim Adjustment 4 9 4 8 Firing Rate Controls 4 9 5 11 4 Air Oil Tank 5 7 5 11 5 Oil Level Sight Gauge 5 7
31. WELL C oli BY PASS BY OTHERS CIRCULATING PIPING BY OTH IPING BY OTHERS PIPING BY 1 C OIL STORAGE TANK NO 6 OIL RECOMMENDED PIPE SIZE TANK TO CIRCULATING PUMP DE LNDE 2 42 54 63 Va DE LNDE 84 105 145 175 210 THIS PIPING LAYOUT IS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 13 Recommended Pipe Size IC 790 revised 2010 2 17 D LND Series Manual INDUSTRIAL COMBUSTION Introduction BACK PRESSURE VALVE SET AT 10 15 PSE H E GATE VALVE gt TI TO DRAWER 2 WAY VALVE ASSEMBL Y ON BURNER o AIR PURGE NOZZLE LINE SOLENOID VALVE Se r PURGE S 3 WAY OPTIONAL Age ON q BURNER 2 RELTEF 4 o VALVE 80 c OIL PREHEATER THERMOMETER SIZED TO FLOW l i es i i LOW PRESSURE CHECK fm HIGH TEMP VALVE V SWITCHES 1 AUXILIARY A Tm 278 H 1 REQUIRED IF PUMP DOES NOT HAVE AN INTERNAL RELIEF D d RELIEF VALVE SET AT 50 PSI NEEDLE s E aw ea OIL METERING CAUCE VACUUM 2 Pump SUPPLIED GAUGE WITH BURNER GATE ba wend VALVE EN CHECK d el e VALVE 3 a um um em um j K E 3 5 Wa of GATE STRAINER VALE STRAINER GATE 2 VALVE IN A COLD OIL START CIRCULATING PIPING BY OTHERS OIL PUMP STORAGE
32. constant volume of oil regardless of viscosity 1 8 11 Separate Compressor Module All Models DE and DEG also DL DMG DM DMG 175 420 burners have a burner mounted oil metering unit and a separate compressor module The system functions as follows IC 790 revised 2010 1 7 D LND Series Manual Introduction INDUSTRIAL COMBUSTION 1 Air Compressor Module Air is supplied by a positive displacement rotary vane compressor This provides a constant volume of atomizing air regardless of pressure The compressor module includes motor air oil reser voir tank air filter and lube oil cooling coil Air enters the compressor through the filter The air flows from the compressor into the air oil separating and reservoir tank Filtering material and baffles separate the lube oil from the compressed air The tank air pressure forces lubricating oil from the tank to the compressor to lubri cate bearings and vanes A sight glass indicates the level of lubricating oil in the air oil reservoir Lubricating oil must be visible in the gauge glass at all times Air compression heat is absorbed in part by the flow of lube oil creating a hot oil mist The air oil mist is cooled by a coil assembly Lube oil is also cooled before entering the compressor 2 Oil Metering The oil metering unit is cored with channels through the housing Fuel oil circulates through these channels keeping the metering unit warm to prevent heavy oils from congealing when
33. determine that the main gas valve opens When this is confirmed turn the burner switch OFF and allow the programmer to finish its cycle Check to see that the gas valve has closed tightly If ignition does not occur turn the burner switch OFF and allow the program mer to recycle for a new ignition trial s Turn the burner ON and after pilot ignition when the flame relay pulls in the slow opening motorized main gas valve is energized Slowly open the downstream manual shutoff gas cock The main flame should ignite at this time The gas valve and air damper continue advancing until high fire is reached 9 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 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 an emergency open the main power switches and close all fuel valves After combus tion adjustments are satisfactorily set allow the heating vessel to slowly reach normal operating pressure or temperature 10 Turn the potentiometer switch to the high fire position Check high fire at this point using combustion instru ments 11 Do not disturb established low fire adjus
34. down with the main electrical power disconnected Inspect the burner carefully and troubleshoot before restarting the unit R N Follow instructions in Chapter 3 for starting and operating 6 2 IC 790 revised 2010 D LND Series Manual 6 3 Troubleshooting INDUSTRIAL COMBUSTION 6 3 Troubleshooting Problem Solution Burner Does Not Start 1 No voltage at 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 reguires 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 e Heavy oil fired unit oil temperature below minimum settings 4 Fuel valve interlock circuit not completed a Fuel valve auxiliary switch not closed Problem Solution No Ignition 1 Lack of spark a Electrode grounded or porcelain cracked b Improper electrode setting C Loose terminal on ignition cable cable shorted d Inoperative ignition transformer
35. 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 GasFired 1 Close the pilot and main line manual gas valves 2 Start the burner and at the time of the pilot trial with just the electrical ignition system energized the flame relay should not pull in be energized 3 Upon completion of a successful test proceed with startup procedures 4 3 2 Oil Fired 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 the 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 s Reconnect the power supply and proceed with startup procedures gt 9 4 2 IC 790 revised 2010 D LND Series Manual 4 4 Gas System INDUSTRIAL COMBUSTION 4 4 Gas System 4 4 1 Gas Pressure Gas must be supplied at a pressure high enough to overcome the pressure loss in the burner gas train and fur nace pressure while running at full input Refer to the nameplate inside the control panel for gas pressure reguire ments at the tr
36. flame relay to pull in 3 2 1 Gas Fired 1 Close the pilot and the main line manual gas valves 2 Start the burner and at the time of the pilot trial with just the electrical ignition system energized the flame relay should not pull in be energized 3 Upon completion of a successful test proceed with startup procedures 3 2 2 Oil Fired 1 disconnect the electrical power to the burner 2 Disconnect the electric oil safety shutoff valve 3 Reconnect electric power to the burner IC 790 revised 2010 3 3 D LND Series Manual Operation INDUSTRIAL COMBUSTION 4 Closethe pilot line manual gas valve if used 5 Start the burner and at the time of the pilot trial with just the electrical ignition system energized the flame relay should not pull in 6 Upon completion of a successful test disconnect the power supply 7 Reconnectthe oil safety shutoff valve and turn on the manual pilot gas valve s Reconnectthe 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 A normal setting is 3 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
37. meter jack for this purpose At initial startup and during planned mainte nance test the pilot flame signal pilot turndown and safety switch lockout A Warning Read the flame safeguard manual and fully understand its contents before attempting to operate this eguipment Fail ure to do so may result in serious personal injury or death 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 A Warning Keep fingers away from the combustion air intake below the damper The damper is actuated with sufficient force to cause severe injury Repeat the procedure until the high fire rate is reached Always make high and intermediate rate adjustments when the burner has reached the low fire position DO NOT disturb the low fire setting 3 4 Startup Sequence 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 e Power is present at the control panel 3 4 IC 790 revised 2010 D LND Series Manual 3 5 Automatic Shutdown INDUSTRIAL COMBUSTION
38. regularly Loss of oil will damage the compressor Fill the tank with non detergent SAE30 oil to a level midway up the sight glass Do not overfill the tank For a normal environment use SAE30 oil For a 322 F and below environment sue SAE 10 oil Change the oil every 2000 hours of operation 3 1 5 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 reg ulator 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 remain closed until the programmer has cycled through pre purge and pilot sequences to deter mine that the main gas valve opens Turn the burner switch OFF and let the programmer finish its cycle Check to see that the gas valve closes tightly Set the high and low gas pressure switches Check for leaks and determine there is adequate gas pressure available at the burner for operating at full capac ity Check with the local utility if necessary Check gas pressure at the pilot and the main burner Close the man ual gas valve 3 2 Electrical Interference Test Prior to putting the burner into service conduct the following test to ascertain that the ignition spark will not cause the
39. sure to static pressure prior to air entry into the blast tube STATOR CONE DIFFUSER IMPELLER ROTARTY AIR DAMPER BOX FIGURE 1 1 Damper Impeller and Stator Cone 1 6 Firing Rate Controls Regardless of the fuel used burner input is fully modulated between low fire and high fire on boiler demand The firing rate is controlled by the potentiometer regulated modulating motor The combustion air control damper oil IC 790 revised 2010 1 3 D LND Series Manual Introduction INDUSTRIAL COMBUSTION metering pump and or gas volume butterfly valve are controlled through variable rate rod and lever linkages The modulating motor rotates 902 from low to high position Flow rate through each component is adjusted by posi tioning the control rods on the levers and the angular position of levers on shafts The lever on the modulating motor shafts actuate the high fire position proving switch 1 7 Firing Head Access to the firing head is provided by swinging open the impeller housing First disconnect the damper link age release the housing latch and swing the housing to the open position An internal gas pilot is standard on all burners Pilot gas pressure is adjusted at the pilot pressure regulator 1 GAS PILOT ASSEMBLY WITH ELECTRIC SPARK KANTOR D AIR ATOMIZING GIL NOZZLE SINGLE OR DUAL 3 FLAME SCANNER AJRDSFUSEN GAS PORTS IN SURROUNDING MANFOLD amp REFRACTORY OVEN
40. tS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONALEQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 9 Recommended Pipe Size IC 790 revised 2010 D LND Series Manual 2 13 INDUSTRIAL COMBUSTION Introduction OIL PREHEATER SIZED TO FLOW REQUIRED IF PUMP DOES NOT HAVE AN INTERNAL RELIEF RELIEF VALVE SET AT 50 PSI VACUUM GAUGE BACK PRESSURE VALVE SET AT 10 15 PSI TO DRAWER ASSEMBLY mm vm mm el AIR PURGE SOLENOID CHECK NOZZLE LINE TVE VALVE PURGE OPTIONAL 2 WAY VALVE ER OIL METERING PUMP SUPPLIED WITH BURNER feet to e Low pressure E 5 HIGH TEMP SWITCHES EEN 1 Gr PRESSURE GAUGE amp NEEDLE AUXILIARY TRIM HEATER PIPING BY OTHERS PIPING BY 1 NO 4 amp 5 OIL RECOMMENDED PIPE SIZE TANK TO CIRCULATING PUMP CIRC OIL PUMP TO BURNER amp RETURN DM LNDM 42 54 DM LNDM 42 54 THIS PIPING LAYOUT IS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 10 Recommended Pipe Size 2 14 IC 790 revised 2010 D LND Series Manual 2 13 Installation Checklist INDUSTRIAL COMBUSTION OIL PREHEATER SIZED TO FLOW REQUIRED IF PUMP DOES NOT HAVE AN INTERNAL RELIEF RELIEF VALVE SET AT 50 PSI VACUUM GAUGE STORAGE TANK BACK PRESSURE VALVE SET AT 10 15 PSI TO DRAWER ASSEMB
41. the supply entrance and pass through the back pressure valve to the return line and on to the tank Metered oil is pumped by the metering pump to the common port of a 3 way valve With the 3 way valve de energized the metered oil returns to the tank through the back pressure valve and return line When the 3 way valve is energized metered oil is passed on to the burner oil nozzle and atomized by air from the compres sor The proper strainers check valves vacuum and pressure gauges etc should be installed as indicated All lines should be pressure tested after installation 2 6 IC 790 revised 2010 D LND Series Manual 2 7 Oil Circulating Loop Operation INDUSTRIAL OMBUSTION eng BACK PRESSURE TO BURNER NOZZLE WHEN REGULATING VALVE Pt ENERGIZED SET 10 TO 15 PSI 3 WAY OIL P Ze VALVE P METERED OIL FROM 3 WAY VALVE WHEN DENERGIZED a 4 gt lt c Na 2 JC AIR IF ANY gt A TO COMMON METER OL OF 3 WAY Ge ma RETURN TO P d VALVE STORAGE TANK 20 MINIMUM RECOMMENDED Ki PRESSURE GAUGE OIL SUPPLY TO BURNER FROM CIRC PUMP OIL STRAINER FIGURE 2 6 Typical Oil Supply Loop 2 7 Oil Circulating Loop Operation No 2 Oil Refer to Figures 2 7 to 2 9 at the end of this chapter No 4 amp 5 Oil Refer to Figures 2 10 to 2 12 at the end of this chapter See Section 2 9 for heater operation No 6 Oil Refer to Figures 2 13 amp 2 14 at the end of this chapte
42. 1192 Valve Gas Butterfly 2 F P 1 940 1257 Valve Gas Butterfly 2 R P 1 1 940 1193 Valve Gas Butterfly 2 1 2 R P 1 940 1230 Valve Gas Butterfly 2 1 2 F P 1 940 1194 Valve Gas Butterfly 3 R P 1 1 1 940 1195 Valve Gas Butterfly 4 R P 1 1 Firing Head Assemblies Quantity Item Part No Description 315 336 378 420 No 1 257 154 Manifold Assembly Gas Firing Head 1 257 165 Manifold Assembly Gas Firing Head 1 257 164 Manifold Assembly Gas Firing Head 1 1 2 32 1099 Gasket Mounting Dry Oven 1 32 1132 Gasket Mounting Dry Oven 1 1 1 3 279 77 Dry Oven Assembly 1 279 138 Dry Oven Assembly 1 1 1 4 42 52 Spud Gas Orifice Protection 312 O D 5 5 5 5 5 940 1195 Valve Gas Butterfly 4 R P 1 1 1 1 6 940 1230 Valve Gas Butterfly 2 1 2 F P 1 1 IC 790 revised 2010 9 37 D LND Series Manual INDUSTRIAL COMBUSTION Parts Lists and Drawings 9 4 18 Oil Air Tank DL DM42 145 Oil Air Tank Assemblies Ouantity Item Part No Description 42 54 63 84 105 145 No 1 941 187 Valve Needle Shutoff T 1 1 1 1 1 2 850 3 Gauge Pressure 0 60 PSI 1 1 1 1 1 1 3 195 256 Tank Assembly Air Oil 350 Cu In 1 1 1 1 1 1 4 940 1200 Valve Check 1 4 Horizontal 1 1 1 1 1 1 5 851 176 Glass Sight Oil Level 3 Centre 1 1 1 1 1 1 9 38 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL CO
43. 16 16 16 11 313 15 Cam Assembly Right Hand 2 2 2 1 12 476 84 Linkage Cam Follower Assembly Gas 1 1 1 1 476 82 Linkage Cam Follower Assembly Oil 1 1 1 1 13 2 13 Am Linkage 5 16 Shaft 17 Holes 1 1 1 1 14 69 303 Roller Guide Assembly 2 2 2 2 15 8 1356 Bracket Linkage Arm Mounting 2 2 2 2 16 74 504 Shaft Linkage Arm Mounting Single Spring Gas 1 1 1 1 74 506 Shaft Linkage Arm Mounting Double Spring Oil 1 1 1 1 17 807 339 Bearing Nylon 3 8 1 0 2 2 2 2 18 82 140 Spring Cam Assembly Return Gas 1 1 1 1 82 155 Spring Cam Assembly Return Oil 1 1 1 1 19 2 184 Arm Linkage 3 4 Shaft X 3 Slot 1 1 IC 790 revised 2010 9 51 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 26 Modulation Cam Trim Low NOx or Left Hand Gas LEFT HAND GAS BUTTERFLY ONLY 9 52 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Standard Modulation Ouantity Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 894 1345 Motor Modulation 120V 35 Sec 1 1 1 1 1 894 1346 Motor Modulation 24V 30 Sec 1 1 1 1 1 2 18 149 Collar Steel 1 1 1 1 1 3 807 335 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 1 807 341 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 1 4 10 322 Bushing Mod Motor Contro
44. 2 2 Way 1 1 N C DL Valve Oil Solenoid 1 2 2 Way 1 1 NC DM Valve Oil Solenoid 1 2 2 Way 1 1 1 1 1 1 1 1 N C DE 940 1233 Valve Oil Motorized W P OC DE 1 1 1 1 Valve Oil Motorized W POC DM 1 1 1 1 Valve Oil Motorized W POC DE 1 1 1 1 10 940 1224 Valve Relief 1 2 60 PSI 1 1 1 1 1 1 1 1 1 1 1 1 9 44 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Oil Metering Assemblies Ouantity Item Part No Description 378 420 No 1 894 936 Motor 3 4 HP 1 1 2 40 296 Housing Mounting Oil Pump to Motor 1 1 3 19 342 Cover Drive Coupling Access 1 1 4 819 105 Coupling Drive 5 8 X 5 8 Bore 1 1 5 695 112 Metering Head Assembly Oil 300L 1 1 6 282 13 Stop Ass y Override Metering Head 1 1 7 476 53 Linkage Ass y Limiting Arm 9 Holes 5 16 1 1 8 940 1372 Valve Oil Solenoid 1 2 2 Way N C DL 1 1 Valve Oil Solenoid 1 2 2 Way N C DM 1 1 Valve Oil Solenoid 1 2 2 Way N C DE 1 1 9 940 1233 Valve Oil Motorized W POC DL 1 1 Valve Oil Motorized W POC DM 1 1 Valve Oil Motorized W POC DE 1 1 10 940 1224 Valve Relief 1 2 60 PSI 1 1 IC 790 revised 2010 9 45 D LND Series Manual INDUSTRIAL COMBUSTION 9 4 22 Oil Metering Assembly D378 420 9 46 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION
45. 3 1337 Chassis E110 1 1 1 1 IC 790 revised 2010 9 21 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 10 Control Package Honeywell 9 22 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Honeywell Control Package Ouantity d Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 833 1278 Base Controller 1 1 1 1 1 1 1 1 1 1 2 833 1335 Control Keyboard Display Module 1 1 1 1 1 1 1 1 1 1 3 833 1276 Controller Program 1 1 1 1 1 1 1 1 1 1 4 832 1067 Amplifier Infrared 3 Second Non Self Check 1 1 1 1 1 1 1 1 1 1 832 1069 Amplifier Ultra Violet 3 Second 1 1 1 1 1 1 1 1 1 1 5 832 1070 Timer 30 Second 1 1 1 1 1 1 1 1 1 1 832 1065 Timer 60 Second 1 1 1 1 1 1 1 1 1 1 832 1066 Timer 90 Second 1 1 1 1 1 1 1 1 1 1 Honeywell Control Package Quantity Item Part No Description 315 336 378 420 No 1 833 1278 Base Controller 1 1 1 1 2 833 1335 Control Keyboard Display Module 1 1 1 1 3 833 1276 Controller Program 1 1 1 1 4 832 1067 Amplifier Infrared 3 Second Non Self Check 1 1 1 1 832 1069 Amplifier Ultra Violet 3 Seconds 1 1 1 1 5 832 1070 Timer 30 Second 1 1 1 1 832 1065 Timer 60 Second 1 1 1 1 832 1066 Timer 90 Second 1 1 1 1 IC 790 revised 2010 9 23 D LND Series M
46. 42 P 3 360 54 P 4 200 3 360 63 P 5 250 4 200 84 S 6 300 5 250 84 P 7 350 6 300 105 P 8 400 7 350 145 5 10 500 8 400 145 P 12 600 10 500 175 P 14 700 12 600 210 P 16 800 14 700 252 P 21 000 16 800 300 P 25 200 21 000 315 P 29 400 N A 336 P 31 500 N A 378 P 33 600 N A 420 P 37 800 N A Gas input based on natural gas at 1 000 But cu ft and 0 60 specific gravity and 60 Hz 8 2 IC 790 revised 2010 D LND Series Manual 8 2 Description INDUSTRIAL COMBUSTION Burner Size Max Burner Oil Input U S G P H lt 30 ppm lt 20 ppm 42 P 24 54 P 30 24 63 P 38 30 84 S 45 38 84 P 53 45 105 P 60 53 145 5 75 60 145 90 75 175 105 90 210P 120 105 252P 150 120 300 P 180 150 315P 215 N A 336 P 225 N A 378 P 240 N A 420 P 270 N A Oil input based on No 2 Oil at 140 000 Btu gal and 60 Hz 8 2 Description 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 gualified Industrial Combustion Service Representative The Industrial Combustion Flue Gas Recirculation FGR system is designed to reduce NOx emissions from boil ers retrofitted with Industrial Combustion burners by adding a percentage of flue gas to the combustion process A burner combustion
47. 77 106 Nozzle Body Assembly 1 1 2 X 12 Nozzle Thds Models DE DEG 1 8 82 33 Spring Nozzle Compression 5 FL X 312 1 0 X 072 All Models Except DE DEG 1 82 129 Spring Nozzle Compression 6 FL X 312 1 0 X 082 Models DE DEG 1 82 129 Spring Nozzle Compression 6 FL X 312 1 0 X 082 All Models 1 82 129 Spring Nozzle Compression 6 FL X 312 1 0 X 082 All Models Except DE DEG 1 82 128 Spring Nozzle Compression 732 FL X 405 I D X 092 Models DE DEG 1 9 528 13 Nozzle Assembly Models DL DLG 1 528 36 Nozzle Assembly Models DL DLG 1 528 34 Nozzle Assembly Models DL DLG 1 528 32 Nozzle Assembly Models DG DM DMG 1 528 36 Nozzle Assembly Models DG DM DMG 1 528 34 Nozzle Assembly Models DG DM DMG 1 528 31 Nozzle Assembly Models DE DEG 1 528 24 Nozzle Assembly Models DE DEG 1 528 25 Nozzle Assembly Models DE DEG 1 10 275 234 Diffuser Assembly Air Models DL DLG 1 275 225 Diffuser Assembly Air Models DL DLG 1 275 167 Diffuser Assembly Air Standard Models DL DLG 1 275 234 Diffuser Assembly Air Standard Models DG DM DMG 1 275 225 Diffuser Assembly Air Standard Models DG DM DMG 1 275 167 Diffuser Assembly Air Standard Models DG DM DMG 1 275 237 Diffuser Assembly Air Standard Models DE DEG 1 1 275 167 Diffuser Assembly Air Standard Models DE DEG 1 11 8 1042 Bracket Nozzle Support 1 1 1 8 1095 Bracket Nozzle Support 1 12 8 1026 Bracket Assembly Draw
48. 8 Pad Motor Support 1 1 12 265 142 Stator Cone Assembly 1 1 13 19 530 Access Cover 1 1 14 914 205 External Retaining Snap Ring 1 1 15 56 290 Hinge Pin 1 1 16 43 13 Latch Toggle Clamp 2 2 17 40 403 Fan Housing Assembly 1 1 18 32 1060 Gasket Fan Housing Seal 1 1 IC 790 revised 2010 9 13 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 6 Compressor Set D42 145 9 14 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Separate Compressor Modules Ouantity Item Part No Description 42 54 63 84 105 145 No 1 940 1205 Valve Check 3 4 Horizontal 1 1 1 1 1 1 2 941 562 Valve Shutoff 3 4 NPT Butterball 1 1 1 1 941 584 Valve Shutoff 1 1 4 NPT Butterball 1 1 3 923 112 Filter Air 1 1 I 1 1 1 4 894 1291 Motor 3 HP 1 1 1 1 1 894 1302 Motor 5 HP 1 5 848 499 Box Electrical W Cover 1 1 1 1 1 1 6 29 841 Flange Compressor Mounting 1 1 1 1 7 505 169 Compressor Assembly Air 2 Single Shaft 1 1 505 152 Compressor Assembly Air 2 3 4 Single Shaft 1 1 8 10 315 Bushing Oil Filter 1 1 1 1 1 1 9 843 106 Filter Oil 1 1 1 1 1 1 10 3 361 Base Assembly Compressor Set 1 1 1 1 1 1 11 809 220 Belt V 1 1 1 1 1 1 12 921 526 Sheave 3 45 PD X 5 8 Bore 1B Groove 1 1 1 1 921 525 Sheave 2 9 PD X 7 8
49. Air 8 4 Models DL DLG 1 695 90 Meter amp Compressor Assembly Oil Air 5 4 Models DM DMG 1 695 92 Meter amp Compressor Assembly Oil Air 6 4 Models DM DMG 1 12 695 64 Meter amp Compressor Assembly Oil Air 5 5 Models DM DMG 1 12 695 66 Meter amp Compressor Assembly Oil Air 7 5 Models DM DMG 1 7 287 1 Arm Assembly 1 1 1 1 8 17 143 Coil Assembly Cooling 1 1 1 1 9 8 1572 Bracket Cooling Coil Mounting 2 2 8 1260 Bracket Cooling coil Mounting 2 2 10 923 115 Filter Air 1 1 1 1 1 1 11 940 1169 Valve Check 1 2 Horizontal 1 1 12 695 101 Meter amp Compressor Assembly Oil Air 7 6 E Style Models DL DLG 1 695 78 Meter amp Compressor Assembly Oil Air 8 6 E Style Models DL DLG 1 6 695 90 Meter amp Compressor Assembly Oil Air 7 7 E Style Models DM DMG 1 6 695 92 Meter amp Compressor Assembly Oil Air 6 4 E Style Models DM DMG 1 13 282 13 Stop Assembly Override M etering Head 1 1 1 1 1 1 14 476 53 Linkage Assembly Limiting Arm 9 Holes 5 16 1 1 1 1 1 1 15 940 1142 Valve Oil Solenoid 3 8 2 Way N C 1 1 1 1 940 1372 Valve Oil Solenoid 1 2 2 Way N C 1 1 16 940 1224 Valve Relief 1 2 60 PSI 1 1 1 1 1 1 17 940 1347 Valve Oil Solenoid 3 8 3 Way N C 1 1 1 1 940 1348 Valve Oil Solenoid 1 2 3 Way N C 1 1 9 42 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 21 Oil Metering Assembly DL DLG DM DMG175 420 amp DE DEG42 420
50. BURNER MOUNTING DETAILS FOR SCOTCH MARINE BOILERS FIGURE 2 4 Scotch Marine Burner Mounting Details 2 4 Packing Plastic Refractory Around Oven 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 plastic refractory from the front to the rear parallel to the outside surface of the dry oven 2 5 Separate Compressor Module For oil burners supplied with the separate compressor module piping to the burner is installed as shown in Fig ure 2 5 Earlier models have the oil cooler finned coil located below the damper The earliest units used a coil in IC 790 revised 2010 2 5 D LND Series Manual Introduction INDUSTRIAL COMBUSTION the blast tube but piping to the compressor and tank is essentially similar Copper tubing for the installation is not supplied with the burner BURNER BLAST TUBETRAY AIRTO BURNER NOZZLE PRESSURE AIR OIL ATOMIZING GAUGE BREATHER FILTER AIRTO NOZZLE OIL AIR TANK TO ATOMIZING AIR PRESSURE SW SIGHT GLASS OIL AIR TANK Ba DRAIN PLUG RNY QR MM MN NNNM A d d i KN KO KN MANN SS 000000060000 XXXXXXXXXXXX XXXXXXXXXXXX 00000000000 QOQOQOQOQQQ DOOOOOODOO00
51. C 790 revised 2010 9 25 D LND Series Manual INDUSTRIAL COMBUSTION 9 4 12 Damper Assembly LND42 420 9 26 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Damper Assemblies Ouantity d Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 427 117 Damper Assembly Air 4 FGR Inlet 1 1 427 127 Damper Assembly Air 6 FGR Inlet 1 1 1 1 1 427 113 Damper Assembly Air 6 FGR Inlet 1 1 427 129 Damper Assembly Air 8 FGR Inlet 1 1 427 114 Damper Assembly Air 8 FGR Inlet 1 1 427 138 Damper Assembly Air 10 FGR Inlet 1 2 32 1144 Gasket Tadpole Tape 3 8 Bulb X 1 Wide 1 1 1 1 1 1 1 1 1 1 3 8 1272 Bracket Damper High Fire Switch 1 1 1 1 1 1 1 1 1 1 4 836 301 Switch High Fire Interlock 1 1 1 1 1 1 1 1 1 1 5 2 184 Arm Linkage Assembly 1 1 1 1 1 1 1 1 1 1 6 807 335 Bearing Flanged 2 PT Damper Shaft 3 4 2 2 2 2 2 807 333 Bearing Square 4 PT Damper Shaft 3 4 2 2 2 2 2 7 18 149 Collar 8 2 189 Arm Linkage Assembly High Fire Switch 1 1 1 1 1 1 1 1 1 1 Damper Assemblies Quantity Item Part No Description 315 336 378 420 No 1 427 117 Damper Assembly Air 10 FGR Inlet T 1 1 1 2 32 1126 Gasket 1 1 1 1 3 8 1272 Bracket Damper High Fire Switch 1 1 1 1 4 836 301 Switch High Fi
52. D LND SERIES Installation Operation and Service Manual INDUSTRIAL COMBUSTION A WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SER VICE THIS EQUIPMENT IC 790 10 10 USTRIAL COMBUSTION D LND SERIES Installation Operation and Service Manual Manual Number 1C 790 Release Date October 2010 INDUSTRIAL COMBUSTION Copyright 2010 by Industrial Combustion All rights reserved No part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means without the prior written consent of Industrial Combustion Industrial Combustion 351 21st Street Monroe WI 53566 608 325 3141 www ind comb com INDUSTRIAL COMBUSTION PREFACE Warning and caution references have been made in this manual and should be adhered to for smooth operation of the burner to others A Warning This symbol precedes information which if disregarded may result in injury to the user of the burner or N Caution This symbol precedes information which if disregarded may result in damage to the burner NOTE This symbol precedes information which is vital to the operation or maintenance of the burner Model designations are based on the type of fuel s to be fired and the amount of furnace pressure to be overcome Burner size is based on firing rate rated input in Btu hr
53. E REGULATOR TYPICAL UL GAS PIPING OVER 12 500 000 BTU FULL MODULATION MODELS D LN 378 amp 420 1 FULL SIZE 1 4 OR LARGER PIPE TO BE RUN FROM THE VENT OPENING TO OUTSIDE OF BUILDING 2 NO TRAPS ALLOWED IN VENT LINE 3 VENT LINE SHALL TERMINATE AWAY FROM ALL DOORS AND WINDOWS 4 PROVISIONS SHALL BE MADE TO PREVENT FOREIGN OBJECTS FROM ENTERING VENT PIPING 1 NORMALLY OPEN VENT VALVE LINE SHALL BE HALF OF THE MAIN GAS TRAIN PIPING SIZE 3 4 MIN FIGURE 2 18 Typical UL Gas Piping LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE BUTTERFLY SHUTOFF COCK ATTA HI TO REGULATOR BURNER MAIN lt GAS eHUTOFF Gas VALVE VALVE VALVE W P O C TO BURNER rr VALVE REGULATOR TYPICAL UL GAS PIPING OVER 12 500 000 BTU FULL MODULATION MODELS D LN 378 amp 420 1 FULL SIZE 1 4 OR LARGER PIPE TO BE RUN FROM THE VENT OPENING TO OUTSIDE OF BUILDING 2 NO TRAPS ALLOWED IN VENT LINE 3 VENT LINE SHALL TERMINATE AWAY FROM ALL DOORS AND WINDOWS 4 PROVISIONS SHALL BE MADE TO PREVENT FOREIGN OBJECTS FROM ENTERING VENT PIPING 1 NORMALLY OPEN VENT VALVE LINE SHALL BE HALF OF THE MAIN GAS TRAIN PIPING SIZE 3 4 MIN THESE PIPING LAYOUTS ARE FOR REFERENCE ONLY AND ARE SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 19 Typical UL Gas Piping 2 21 IC 790 revised 2010 D LND Series Manual e s D G o 2 g G o A
54. GAS PILOT INLET CONNECTION gt ATOMIZING AIR UNE gt BECTROOELEAD ID SCANNER LEAD H RBELOLIMET t BLAST TUBE 1 gt DRY OVEN GASKET 14 GASINLET FIGURE 1 2 Firing Head Assembly 1 4 IC 790 revised 2010 D LND Series Manual 1 8 Oil System Air Atomizing INDUSTRIAL COMBUSTION MAIN GAS ORIF ICES MAIN ORIFICES PRESSURE GAUGE v SPUDS wech PRESSURE GAUGE MAIN ORIFICES BUTTERFLY VALVE GAS SPUDS FIGURE 1 3 Dual Gas Manifold 1 8 Oil System Air Atomizing D Model burners use compressed air for atomization Atomizing air is independent of combustion air Either of two air oil systems are used depending on burner size and fuel ONe system uses an integral air compressor oil metering unit mounted on the burner and is driven by a separate motor The other system is supplied with a sep arate compressor module for mounting near the burner 1 8 1 3 Way Solenoid Valve Metered oil enters the common port of the 3 way solenoid valve During shutdown pre and post purge the valve is de energized N C port closed and all metered fuel oil returns to the storage tank When the valve is ener gized metered oil is directed to the nozzle through the N C port 1 8 2 Nozzle Assembly The nozzle assembly consists of four main parts Body e Compression Spring e Swirler e Tip The swirler is held against the nozzle tip by the compression spring IC 790 revised 2010
55. Gas Valve Refer to the adjustment section to setup the burner In the low fire position the secondary valve controlling the pre mix spuds is almost closed After all adjustments are made throughout the modulating range go back and relight the burner Upon startup check that the fire is not burning behind the diffuser If this happens close the secondary valve until this situation is corrected Repeat several times IC 790 revised 2010 8 7 D LND Series Manual Flue Gas Recirculation INDUSTRIAL COMBUSTION MAIN ORIFICES PRESSURE GAUGE SPUDS PRESSURE GAUGE EL OPTIONAL PRE MIX SPUDS GAUGE CONNECT 1 ON PRIMARY GAS VALVE SECONDARY GAS VALVE LEFT OR RIGHT SIDE GAS TRAIN CONNECTION FIGURE 8 6 20 PPM Head Assembly 8 8 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 9 Parts Lists and Drawings 9 1 Instructions When ordering repair parts please include e Part Number e Burner Serial Number e Model e Size e Voltage This information can be obtained from the burner nameplate and the data label voltage on the panel door When ordering fan wheels give the overall diameter width bore manufacturer and motor HP This parts section does not include such common hardware items as nuts washers electrical parts copper tub ing flare fittings and pipe Items such as these can be readily purchased locally The following parts are sold on an exchange ba
56. IRCULATING PIPING BY OTHERS STORAGE PUMP TANK WS os PIPING BY LC NO 2 OIL RECOMMENDED PIPE SIZE TANK TO CIRCULATING PUMP CIRC OIL PUMP TO BURNER amp RETURN 2 DLLNDL 1 DLLNDL 105 145 175 210 105 145 175 210 THIS PIPING LAYOUT IS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONALEQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 8 Recommended Pipe Size 2 12 IC 790 revised 2010 D LND Series Manual 2 13 Installation Checklist INDUSTRIAL COMBUSTION BACK PRESSURE VALVE SET 10 15 PSI 2 WAY VALVE ON BURNER TO DRAWER A I ASSEMBLY 3 WAY VALVE 2 RELIEF 4 ON BURNER VALVE f i l LOWOIL PRESSURE J SWITCH 1 CHECK PRESSURE i D VALVE REQUIRED IF PUMP DOES NOT GAUGE amp ae ee d 1 HAVE AN INTERNAL RELIEF NEEDLE i RELIEF VALVE SET AT 50 PSI VALVE OIL METERING 2 PUMP SUPPLIED n T I SH GATE WITH BURNER GAUGE HPU VALVE le 3 A NI GATE EN ox d da R KC Ke VALVE 5 VALVE E o_o 1 2 01 STRAINER GATE z z STRAINER we 2 GATE a 15 E gt vave JN KM OIL PIPING BY OTHERS STORAGE mx SK Mon PIPING BY I C NO 2 OIL RECOMMENDED PIPE SIZE TANK TO ORCULATING PUMP ORC OIL PUMP TO BURNER amp RETURN OLLNDL 252 300 315 336 DLLNDL 252 300 315 336 378 420 378 420 THIS PIPING LAYOUT
57. K BOILER FRONT PLATE BURNER FLANGE An PACK WITH PLASTIC REFRACTORY v IKAISER MONO T 9 AIR SET OR EQUAL RAM FROM FRONT TO REAR NNN E DIE a WRAP DRY OVEN z WITH KAO WOOL ICOAT BOTH SIDES WITH TROWLEZE COAT OUTER CIRCUMFERENCE OF DRY OVEN WITH TROWLEZE DRY OVEN SUPPLIED WITH BURNER STEEL WRAPPER ON CONE 1 GASKET SUPPLIED WITH BURNER NOTES I LAY THE DRY OVEN ON THE FLOOR WITH THE STUDS UP CAREFULLY PRESS THE GASKET OVER THE STUDS 2 UFT THE DRY OVEN ONTO THE BURNER FLANGE AND GENTLY TIGHTEN THE BOLTS 3 MAKE SURE THE DRY OVEN IS CENTERED ON THE BURNER FLANGE SO THE SPACE IS EQUAL ALL AROUND THE BURNER BLAST TUBE 4 MAKE SURE THAT NONE OF THE GASKET 15 PROTRUDING INTO THE AIR STREAM TIGHTEN THE DRY OVEN NUTS 5 WRAP THE DRY OVEN WITH TROWLEZE COATED KAO WOOL AND LIFT THE BURNER ONTO THE BURNER STUDS AND BOLT SECURELY IN PLACE 6 FINISH REFRACTORY WORK INSIDE FURNACE BURNER MOUNTING DETAILS FOR FIREBOX AND WATERTUBE BOILERS FIGURE 2 3 Firebox and Watertube Burner Mounting Details Securely support the burner pedestal on the floor or foundation Allow enough clearance at the rear of the burner to allow the housing to swing open for service and maintenance Figure 2 2 shows an installation with typical burner support Many boilers including some Scotch Marine types do not have sufficiently rigid front plates and require additional support under the burner base B
58. LY AIR PURGE SOLENOID VALVE CHECK NOZZLE LINE VALVE PURGE OPTIONAL 2 WAY VALVE J ON BURNER LOW PRESSURE HIGH TEMP SWITCHES AUXILIARY Ci PRESSURE GAUGE amp jp NEEDLE ES PRESSURE VALVE OIL METERING PUMP SUPPL TED PIPING BY OTHERS gt PIPING BY NO 4 amp 5 OIL RECOMMENDED PIPE SIZE TANK TO CIRCULATING PUMP CIRC OIL PUMP TO BURNER amp RETURN DM LNDM 63 84 105 175 210 DM LNDM 63 84 105 THIS PIPING LAYOUT IS FOR REFERENCE ONLY ANO IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 11 Recommended Pipe Size IC 790 revised 2010 2 15 D LND Series Manual INDUSTRIAL COMBUSTION Introduction BACK PRESSURE VALVE SET AT 10 15 PSI TO DRAWER 2 WAY VALVE ASSEMBLY ON BURNER mm mm mm mm mm mm mm wm mmm wm io AIR PURGE I SOLENOID t VALVE CHECK NOZZLE LINE Nes VALVE 1 PURGE 1 OPTIONAL e poed 3 WAY RELIEF VALVE 148 VOLVE BURNER OIL PREHEATER SIZED TO FLOW Le 9 4 CHECK b LOW PRESSURE ee ame VALVE HIGH TEMP 48 SWITCHES AUXILIARY 4 TRIM CS Ki HEATER REQUIRED IF PUMP DOES NOT PNEsSURE 3 HAVE AN INTERNAL RELIEF RELIEF VALVE SET AT 50 PSI GAUGE amp 1 NEEDLE PRESSURE 1 1 I
59. MBUSTION 9 4 19 Oil Heater D42 420 IC 790 revised 2010 9 39 D LND Series Manual INDUSTRIAL COMBUSTION Parts Lists and Drawings Heater Ouantity e Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 832 690 Heater Electric Oil 3KW 230 3 60 1 1 1 832 689 Heater Electric Oil 5KW 230 3 60 1 1 1 1 832 724 Heater Electric Oil 7KW 230 3 60 1 832 717 Heater Electric Oil LOKW 230 3 60 1 832 718 Heater Electric Oil LOKW 440 3 60 1 2 77 200 Spacer Auxiliary Heater Shim 1 1 1 1 1 1 1 3 257 70 Manifold Assembly 3 KW amp 5 KW Heaters 1 1 1 1 1 1 1 257 72 Manifold Assembly 7 KW amp 10 KW Heaters 1 1 1 4 7 144 U Bolt 3 1 2 1 D X 5 Legs Threaded 1 4 20 2 2 2 2 2 2 2 7 144 U Bolt 4 1 0 X 6 Legs Threaded 1 4 20 2 2 2 5 817 829 Switch Air Oil Pressure 4 12 PSI 1 1 1 1 1 1 1 1 1 1 6 817 620 Switch High Oil Temperature 160 260 Deg 1 1 1 1 1 1 1 1 1 1 7 937 163 Gauge Temperature 50 300 Deg 1 2 NPT 1 1 1 1 1 1 1 1 1 1 Heater Quantity Item PartNo Description 315 336 378 420 No 1 832 718 Heater Electric Oil 10KW 440 3 60 1 1 1 1 3 257 72 Manifold Assembly 7 KW amp 10 KW Heaters 1 1 1 1 4 7 144 U Bolt 4 1 D X 6 Legs Threaded 1 4 20 2 2 2 2 5 817 829 Switch Air Oil Pressure 4 12 PSI 1 1 1 1 6 817 620 Switch High Oil Temperature
60. Modulation 24V 30 Sec 1 1 1 1 1 1 1 3 807 341 Bearing Flanged 2 PT 3 4 Shaft 2 2 2 2 2 2 2 4 10 322 Bushing Mod Motor Control Arm 12 LG 1 1 1 1 1 1 1 7 10 343 Bushing Mod Motor Control Arm 34 11 16 LG 1 1 1 1 1 1 1 8 2 141 Arm Linkage 3 4 Shaft 7 Holes 2 2 2 2 2 2 2 9 2 184 Arm Linkage 3 4 Shaft X 3 Slot 1 1 1 1 1 1 1 10 2 259 Arm Linkage 3 4 Shaft 6 Holes 2 2 2 2 2 2 2 IC 790 revised 2010 D LND Series Manual 9 49 Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 25 Modulation Cam Trim Standard Modulation Ouantity Description 42 54 63 84 105 145 175 210 252 300 0 1 894 1345 Motor Modulation 120V 35 Sec 1 1 1 1 1 894 1346 Motor Modulation 24V 30 Sec 1 1 1 1 1 2 18 149 Collar Steel 1 1 1 1 1 3 807 335 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 1 807 341 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 1 4 10 322 Bushing Mod Motor Control Arm 12 LG 1 1 1 1 1 1 1 1 1 1 5 2 141 Arm Linkage 3 4 Shaft 7 Holes 1 1 1 1 1 1 1 2 259 Arm Linkage 3 4 Shaft 6 Holes 1 1 1 6 82 153 Spring Roller Guide Cam 1 1 1 1 1 1 1 1 1 1 7 36 111 Guide Cam Spring 16 16 16 16 16 16 16 16 16 16 8 71 24 Screw Spring Fastener 2 2 2 2 2 2 2 2 2 2 9 860 301 Screw Locking Set Kit 16 per kit 10 860 299 Screw Set 10 32 X 1 LG Half Dog
61. ON 1 9 1 Main Gas Train Components Depending on the reguirements of the regulating authority the gas control system and gas train may consist of some or all of the following items Component Description Gas Volume Valve The butterfly type valve is positioned by linkage from the modulating motor and controls the rate of flow of gas Main Gas Valves Electrically operated safety shutoff valve s that open to admit gas to the burner Standard UL burners include Models D42 One motorized gas valve and one solenoid valve Models D54 105 One motorized gas valve w closure interlock and one sole noid valve Models D145 420 Two motorized gas valves and one w closure interlock Main Gas Regulator Regulates gas train pressure to specified pressure required at the inlet to the gas train Input is set by main gas pressure regulator adjustment Main Gas Cocks For manual shutoff of the gas supply upstream of the pressure regulator A sec ond shutoff cock downstream of the main gas valve s provides a means of test ing for leakage through the gas valve s High Gas Pressure Switch A pressure actuated switch that remains closed when gas pressure is below a pre selected setting Should the pressure rise above the setting the switch con tacts will open causing main gas valve s to close This switch reguires manual reset after being tripped Low Gas Pressure Switch A pressure actuated switch that remains closed when ga
62. OTOR TERMINAL E Y STRAINER BURNER NOZZLE COMPRESSOR CHECK VALVE or SUPPLIED BY OTHERS FIGURE 7 1 Steam Atomizing System IC 790 revised 2010 7 1 D LND Series Manual Accessories INDUSTRIAL COMBUSTION The steam atomizing line is shipped loose and must be piped and wired to the burner as shown in the diagram below Refer to the wiring diagram for the electrical connection The air compressor is used for cold oil startup Start the boiler with the air atomizing system first Once the boiler reaches operating pressure shut down the unit close the shut off valve on the air line and open the one on the steam line Set the Air Steam switch to the Steam position Restart the unit with the steam atomizing system You must have a minimum of 70 PSI atthe inlet of the steam regulator Open the needle valve to its maximum Adjust your steam pressure with the regula tor to have 30 PSI on the discharge side of the regulator While the unit is purging screw in and adjust the nee dle valve to have 10 15 PSI in low fire Install a pressure gauge to monitor the pressure One or two regulator is supplied depending on the boiler operating steam pressure Follow the instructions in the Chapter 4 Adjust ments to set up the burner Fine tune the steam atomizing with the needle valve 7 3 Air Purge System optional The nozzle line air purge option is used to purge the oil out of the nozzle line usin
63. Point 16 16 16 16 16 16 16 16 16 16 11 313 15 Cam Assembly Right Hand 2 2 2 2 2 2 2 2 2 2 12 476 84 Linkage Cam Follower Assembly Gas 1 1 1 1 1 1 1 1 1 1 476 82 Linkage Cam Follower Assembly Oil 1 1 1 1 1 1 1 1 1 1 13 2 13 Arm Linkage 5 16 Shaft 17 Holes 1 1 1 1 1 1 1 1 1 1 14 69 303 Roller Guide Assembly 2 2 2 2 2 2 2 2 2 2 15 8 1356 Bracket Linkage Arm Mounting 2 2 2 2 2 2 2 2 2 2 16 74 504 Shaft Linkage Arm Mounting Single Spring Gas 1 1 1 1 1 1 1 1 1 1 74 506 Shaft Linkage Arm Mounting Double Spring Oil 1 1 1 1 1 1 1 1 1 1 17 807 339 Bearing Nylon 3 8 1 D 2 2 2 2 2 2 2 2 2 2 18 82 140 Spring Cam Assembly Return Gas 1 1 1 1 1 1 1 1 1 1 82 155 Spring Cam Assembly Return Oil 1 1 1 1 1 1 1 1 1 1 9 50 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Standard Modulation Ouantity Item Part No Description 315 336 378 420 No 1 894 1346 Motor Modutrol 24V 30 Sec 1 1 1 1 3 807 341 Bearing Flanged 2 PT 3 4 Shaft 1 1 1 1 4 10 309 Bushing Mod Motor Control Arm 12 LG 1 1 1 1 5 2 259 Arm Linkage 3 4 Shaft 6 Holes 1 1 1 1 6 82 153 Spring Roller Guide Cam 1 1 1 1 7 36 111 Guide Cam Spring 16 16 16 16 8 71 24 Screw Spring Fastener 2 2 2 2 9 860 301 Screw Locking Set Kit 16 per kit 1 10 860 299 Screw Set 10 32 X 1 LG Half Dog Point 16
64. Selects gas as the firing fuel b Off Position Burner off c Oil Position Selects oil as the firing fuel NOTE When changing from oil to gas fuel allow the programmer to com plete post purge and shutdown before moving the selector switch to the gas position This will allow the interlock circuit to de energize at either the oil air pump or the compressor Control Circuit Breaker Supplementary low overcurrent protection only No larger than 15 amps Auto M anual Modulation Selector a Auto Position Selects boiler modulation control Switch b Manual Position Selects 135 ohm potentiometer for manual modulating control Manual Modulating Control 135 ohm Increases or decreases the burner firing rate manually Signal Lamps a Power On white Illuminates when the control circuit is energized pow ered b Ignition amber Illuminates when the ignition transformer is powered and gas pilot valve is energized open c Main Fuel green Illuminates when the main fuel valve or valves gas or oil are energized open d Flame Failure red Illuminates when the flame safeguard system fails to detect pilot or main flame 1 4 Flame Safeguard Controls The flame safeguard programmer incorporates a flame sensing cell scanner to shut down the burner in the event of pilot flame or main flame failure Other safety controls shut down the burner based on sequence of oper ation as shown in the manufacturer
65. TERING PUMPS 30 125 40 150 dln INTEGRAL OIL AIR SYSTEM 100 250 USED ON MODELS DL DLG 175 TO 420 DM DMG 42 54 DM DMG 175 TO 420 DE DEG 42 TO 420 BURNER AIR IMPELLERS D SERIES SEPARATE AIR COMPRESSOR MODULE 4 USED ON MODELS REAR DL DLG DM DMG 175 TO 420 DE DEG 42TO 420 AUD SEHSES MSIOEES FIGURE 4 7 Motor Rotations IC 790 revised 2010 4 11 D LND Series Manual e s D G o 2 g G o A p ION Adjustments 4 12 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 5 Maintenance A Warning Any cover plates enclosures or guards anchored to the burner or any burner related eguipment must remain in position at all times Only during maintenance and service shutdown can these cover plates enclosures or guards be removed They must be replaced and securely anchored before testing adjusting or running the burner or burner related equipment Z Caution It is important that support is provided for the hosing when in the open position to prevent damage to the hinges and subsequent components 5 1 Overview A maintenance program avoids unnecessary downtime costly repairs and promotes safety It is recommended that a record be maintained of daily weekly monthly and yearly maintenance activities Electrical and mechanical devices require systematic and periodic inspection and maintenance Any autom
66. VEN LINKAGE ARM SETTING LINKAGE ARM FOR OIL METERING DEVICE OR GAS BUTTERFLY VALVE FUEL SETPOINT INPUT LOCKING DRIVE INCREASE SETSCREWS LINKAGE ARM FUEL SETTING INPUT INCREASE FUEL INPUT DECREASE ROLLER GUIDE FUEL INPUT CAM TRIM SETPOINTS TURNING SETSCREW CLOCKWISE WILL INCREASE FUEL INPUT ROLLER GUIDE SETTING FUEL INPUT INCREASE LOW FIRE START POSITION OF ROLLER GUIDE MUST FALL WITHIN THESE LIMITS TENSION INCREASE DECREASE RETURN SPRING TENSION SETTING FIGURE 4 5 Cam Trim Adjustment 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 4 8 Firing Rate Controls Firing rate adjustments are made at the modulating motor linkages to the combustion air inlet damper air oil metering pump and main gas butterfly valve Settings are determined by the operating length of the levers and the angular position on the shafts Increasing the lever lengths on damper pump or valve decreases the flow IC 790 revised 2010 4 9 D LND Series Manual Adjustments INDUSTRIAL COMBUSTION rate Driving and driven levers are approximately parallel but the angles can be adjusted to vary the rate of change The most rapid rod travel occurs when the lever is per
67. ain inlet and manifold The pressures listed are based on nominal 1000 Btu cu ft natural gas at elevations up to 2000 feet above sea level 4 4 2 Gas Flow The volume of gas is measured in cubic feet as determined by a meter reading The gas flow rate required depends on the heating value Btu cu ft The supplying utility can provide this information as well as pressure correction factors To determine the required number of cubic feet per hour of gas divide burner input Btu hr by the heating value Btu cu ft NOTE When checking the input rate make sure no other equipment is operating on the same meter 4 4 3 Gas Pilot Flame Adjustment The gas pilot flame is regulated by adjusting the pressure setting of the pilot regulator Normal setting is 3 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 mainte nance test the pilot flame signal pilot turndown and safety switch lockout A Warning An ultra violet flame sensor electrical spark interference test must be performed after final adjustment See Section 4 3 for additional information 4 4 4 Main Gas Pressure R
68. air fan is used to pull flue gas from the stack through the FGR duct and inject it into the combustion zone Typical sizing for the FGR ducts are shown in Figure 8 4 All FGR duct piping should be covered with a minimum of 2 of insulation and supported as required The following controls are used in the FGR duct for safe operation of the system IC 790 revised 2010 8 3 D LND Series Manual INDUSTRIAL Flue Gas Recirculation COMBUSTION FIGURE 8 1 General Layout of the Burner 8 3 FGR Shutoff Valve The FGR shutoff valve is located as close to the stack as possible A modutrol motor with a 902 stroke opens and closes the FGR shutoff valve in 15 seconds Proof of closure for the shutoff valve is provided by and auxiliary switch in the modutrol motor The modutrol motor has a maximum temperature rating of 1502 F This valve should never be mounted with the motor shaft in a vertical position Dam age 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 MODUTROL MOTOR 2 F G R SHUTOFF VALVE 3 LINKAGE ARM 4 LINKAGE ARM ASSEMBLY 5 GASKET FIGURE 8 2 FGR Shutoff Valve 8 4 IC 790 revised 2010 D LND Series Manual 8 4 FGR Control Valve INDUSTRIAL COMBUSTION 8 4 FGR Control Valve The FGR control valve is mounted to an FGR damper on the burner A burner mounted mod
69. alve action several times to ensure proper operation before attempting to relight the burner 5 13 Electrical System Because of the many types of flame safeguard systems applicable to this equipment complete descriptions of all D Series burner electrical systems are beyond the scope of this manual An individual electrical schematic draw ing is shipped with each burner and complete operation and troubleshooting instructions are available from the various flame safeguard system manufacturers 5 13 1 Electric Motors Motor supply voltage must not vary more than 1096 from nameplate ratings At initial startup and at least once a year thereafter check the motor current with a meter while the burner is in high fire position If the reading exceeds the nameplate rating plus service factor determine the cause and correct it immediately In dusty loca tions clean the motor regularly to assure adequate cooling Lubricate in accordance with the manufacturer s instructions 5 14 Extended Shutdown When shutting down the burner for an extended period of time the operator should use the following general guidelines to protect the burner from its surrounding elements This will add to the operating life of the burner 1 Turn the main electrical disconnect switch to the burner to OFF 2 Close all main fuel valves 3 If the burner operates in a damp environment cover it with plastic to protect all electrical components from moisture R
70. anual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 11 Damper Assembly D42 420 9 24 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Damper Assemblies Ouantity d Part No Description 42 54 63 84 105 145 175 210 252 300 0 1 427 42 Damper Assembly Air 1 1 1 1 1 427 40 Damper Assembly Air 1 1 427 41 Damper Assembly Air 1 1 1 2 32 1124 Gasket 1 1 1 1 1 32 1125 Gasket 1 1 32 1127 Gasket varies 1 1 1 3 8 1272 Bracket Damper High Fire Switch 1 1 1 1 1 1 1 1 1 1 4 836 301 Switch High Fire Air Interlock 1 1 1 1 1 1 1 1 1 1 5 2 141 Arm Linkage Assembly 1 1 1 1 1 1 1 2 259 Arm Linkage Assembly 1 1 1 6 807 335 Bearing Flanged 2 PT Damper Shaft 3 4 2 2 2 2 2 807 333 Bearing Square 4 PT Damper Shaft 3 4 2 2 2 2 2 7 18 149 Collar 2 2 2 2 2 8 2 189 Arm Linkage Assembly High Fire Switch 1 1 1 1 1 1 1 1 1 1 Damper Assemblies Quantity Item Part No Description 315 336 378 420 No 1 427 41 Damper Assembly Air 1 1 427 156 Damper Assembly Air 1 1 2 32 1127 Gasket varies 1 1 32 1126 Gasket 1 1 3 8 1272 Bracket Damper High Fire Switch 1 1 1 1 4 836 301 Switch High Fire Air Interlock 1 1 1 1 5 2 259 Arm Linkage Assembly 1 1 1 1 6 807 333 Bearing Square 4 PT Damper Shaft 3 4 2 2 2 2 I
71. ases under the support leg must be long enough to support the burner when being inserted or withdrawn from the boiler Boilers operating with the combustion pressure above atmospheric pressure must be sealed to prevent escape of combustion products into the boiler room The burner mounting flange is designed to provide for a seal The face of the boiler and burner flange must be sealed with the gasket provided with the burner Carefully place the gasket over the dry oven bolts before it is mounted onto the burner flange The I D of the dry oven is slightly larger than the blast tube I D Make sure the dry oven and burner blast tube are concentric Due to bolt hole tolerances the dry oven may have to be shifted to accom plish this After the dry oven nuts are properly tightened the burner and dry oven assembly can then be mounted into the boiler For maximum safety it is recommended that boilers not operating under pressure should also be sealed 2 4 IC 790 revised 2010 D LND Series Manual 2 4 Packing Plastic Refractory Around Oven INDUSTRIAL COMBUSTION N Caution It is important that you provide support for the housing when in the open position to prevent damage to the hinges and subseguent components 2 M INSULATING BLANKET KAO WOOL CERABLANKET DURABLANKET 1 ON ALL SCOTCH BOILERS REFRACTORY 2 BLOCK INSULATION PROTECTION MUST EXTEND AT LEAST TUBE 2 50 PAST THE TUBE SHEET 2 50 MIN
72. at it has been running for some time e The operator has become thoroughly familiar with both the burner and the manual by this time The points set forth under each heading are brief possible causes suggestions or clues to simplify locating the source of the trouble Methods of correcting the trouble once it has been identified may be found elsewhere in this manual If the burner will not start or operate properly the Troubleshooting section should be referred to for 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 IC 790 revised 2010 6 1 D LND Series Manual Troubleshooting INDUSTRIAL COMBUSTION Costly downtime or delays can be prevented by systematic checks of actual operation against the normal seguence to determine the stage at which performance deviates from normal Following a set routine may possi bly 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 c
73. ated in the line by pump action The cause of a pulsating burner fire can often be traced directly to air leakage in the oil suction line Always be sure suction line joints are absolutely air tight e o NO pm gt 5 11 2 Air Oil Metering Pump N Caution The metering pump is lubricated by fuel oil and must not be operated longer than one minute if it is not pumping oil Failure to comply will result in premature pump failure and void any warranty implied or otherwise Both the integral air oil metering pump for light oil and the heavy oil metering pump are precisely fitted nits employing a seal on the shaft to prevent oil leakage Internal wear can take place due to dirt in the oil and may in time result in excessive clearances reducing pump capacity Once adjusted the pump will continue to operate with a minimum of readjustment If burner failure appears to be caused by the metering pump check the follow ing 1 See that the oil is at a sufficient level in both the fuel oil tank and the air oil tank on the burner Make sure all valves between the fuel oil tank and the burner are open Be sure the oil suction line is not airbound and check the suction line strainer Check the low fire setting of the metering pump to be sure it has not been disturbed Make sure the pump turns freely Inspect the burner oil nozzle for clogging m gt mh Caution Do not attempt to disassemble the oi
74. atic features do not relieve the operator from responsibility but rather free him from certain repetitive chores provid ing time for upkeep and maintenance Unusual noise improper gauge reading leak sign of overheating etc can indicate a developing malfunction requiring corrective action 5 2 Control System Most operating controls require very little maintenance beyond regular inspection Examine electrical connec tions Keep the controls clean Remove any dust from the interior of the control Covers should be left on controls IC 790 revised 2010 5 1 D LND Series Manual Maintenance INDUSTRIAL COMBUSTION 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 5 2 1 Programming Control This control reguires no adjustment nor should any attempt be made to alter contact settings or timing logic Those programmers with contacts may reguire occasional cleaning If so follow instructions given in the manu facturer s bulletin Never use abrasive materials The manufacturer s bulletin also contains troubleshooting infor mation The flame detector lens should be cleaned as often as conditions demand A periodic safety check procedure should be established to test the complete safeguard system Tests should v
75. ation will determine the warranty status be installation date of the unit and date of failure along with the age of the motor determined by the code date 3 If the unit is within warranty the unit will be inspected for cause of failure and repair requirements 4 If the units is within warranty limitations the service station will repair on a No Charge basis 5 f the repairs are extensive the Service Station will contact the motor manufacturer warranty manager to decide if the motor is to be repaired or replaced Exception to the Above Procedure Emergency situations may dictate that because of the distance between user and authorized Service Stations severe damage or interruptions may result The following procedure should be used 1 Select a knowledgeable motor repair shop 2 Repair shop to contact motor manufacturer warranty repair manager detailing repairs necessary along with the complete nameplate data before any repairs are made 3 If any problems occur the Industrial Combustion Parts Department will provide assistance Failure to Follow the Next Procedure Will Result in Repairs Being Made at the Customer s Expense Marathon Electric Electric Motors Warranty Repair Procedure The following procedure must be used for proper replacement and or repair of M arathon Electric Motors that have failed under warranty 1 End user will remove motor from unit and take failed motor to Marathon Electric authorized service statio
76. d SZSZ QN1 B d S01Z QN1 B d SS 1 QN1 10045 B SS L UNT1 MOIS 1M0MS B d SS01 QN1 TYNOTLd0 B a Sv8 0N1 B a S 9 0N1 B d SrS GN1 B d SZY QN1 7300N M3NHhB IC 790 revised 2010 D LND Series Manual 12 5 Valve 5 iping FIGURE SA 8 6 8 6 Blast Tube Temperature Interlock optional INDUSTRIAL COMBUSTION 8 6 Blast Tube Temperature Interlock optional A blast tube temperature interlock device monitors air temperature in the blast tube area of the burner If the blast tube temperature rises above 2002 F maximum An external scanner is used on the low emission burners 8 7 Stack Temperature Interlock optional A 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 252 F below the minimum stack tem perature at low fire nominal 2002 F After the stack temperature rises above the set point the interlock stack temperature rises above the set point the interlock closes and allows the burner to modulate 8 8 20 PPM Design The 20 ppm design features a dual gas manifold Each zone is controlled by a butterfly valve linked to a 14 point adjustment cam The primary large butterfly valve controls the main gas orifices and the secondary small butter fly valve controls the pre mix gas spuds See Figures 8 5 and 8 6 FIGURE 8 5 Secondary
77. d be in accordance with the following prevailing standards e National Fuel Gas Code NFPA No 54 e ANSI No Z 223 1 For Canada e Canadian Gas Association CGA B149 e Canadian Standards Association CSA B140 Gas train components upstream of the butterfly valve are shipped loose These components should be mounted by the installer as close to the butterfly valve as practical Normally the control train is ordered to suit a particu lar code or insurance regulation such as Underwriters Laboratories Inc CGA Factory Mutual or Industrial Risk Insurance Arrange gas piping at the burner so that the burner is accessible for servicing without disassembly The gas pilot supply line must be connected upstream of the main gas regulator If a reducing bushing is required between the house piping and the burner piping it should be close to the burner shutoff valve The gas piping must be internally clean and free of foreign material Before using in service a leak test must be performed 2 13 Installation Checklist All burners are carefully assembled and tested at the factory but before being placed in service all connectors should again be checked for looseness caused during shipment IC 790 revised 2010 2 9 D LND Series Manual Introduction INDUSTRIAL COMBUSTION Check e Electrical terminals in the control panel and on all electrical components e Pipe fittings and unions e Tubing connections e Nuts bolts sc
78. dels DL DLG 1 1 275 243 Diffuser Assembly Air Standard Models DG DM DMG 1 275 244 Diffuser Assembly Air Standard Models DG DM DMG 1 1 275 244 Diffuser Assembly Air Standard Models DE DEG 1 1 1 9 826 40 As Required 1 1 1 10 848 166 Connector Ignition Cable Straight 1 1 1 11 873 93 Electrode Assembly Ignition with Bushing 1 1 1 IC 790 revised 2010 9 29 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 14 Drawer Assembly D84 145 9 30 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Drawer Assemblies Ouantity Item Part No Description 84 105 145 No 1 106 101 Block Oil Air Inlet Manifold 1 2 853 613 O Ring 5 8 O D X 3 32 Thk 1 3 90 241 Tube Assembly Oil Nozzle Deliver 1 1 4 817 Varies 1 1 1 5 90 338 Tube Scanner Sight 9 1 1 1 6 928 44 Clamp Conduit 1 2 1 1 1 7 277 139 Nozzle Body Assembly 22 MM X 1 5 MM Nozzle Thds Models DL DLG 1 277 105 Nozzle Body Assembly 1 1 8 X 16 Nozzle Thds Models DL DLG 1 1 277 139 Nozzle Body Assembly 22 MM X 1 5 MM Nozzle Thds Models DG DM DMG 1 277 105 Nozzle Body Assembly 1 1 8 X 16 Nozzle Thds Models DG DM DMG 1 1 277 105 Nozzle Body Assembly 1 1 8 X 16 Nozzle Thds Models DG DM DMG 1 1 2
79. down 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 Shut down The condition must be corrected and the respective gas pressure switch manually reset before the burner will fire again on gas IC 790 revised 2010 3 5 D LND Series Manual Operation INDUSTRIAL COMBUSTION 3 8 Startup and Operating 3 8 1 Gas Burners 1 Closethe main and pilot gas cocks Make sure the ON OFF switch is in the OFF position and the fuel selector switch is on GAS Actuate the manual reset button ofthe flame safeguard control to close the safety switch contacts Set the MANUAL AUTO switch to MANUAL 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 trans former and the gas pilot solenoid are energized Before proceeding conduct electrical interference and pilot turndown tests if not previously done 7 On initial startup it is recommended that the main gas shutoff cock remain closed until the programmer has cycled through pre purge and pilot seguence Then
80. e through the hole in the diffuser 4 Inspect the lead wire to the ignition electrode It must be firmly attached and the insulation should be clean and free of cracks 5 2 IC 790 revised 2010 D LND Series Manual 5 4 Firing Head Inspection INDUSTRIAL COMBUSTION 5 The oil nozzle should be inspected periodically depending on the grade of oil burned and the cleanliness of the environment FRONT OF DIFFUSER TO NOZZLE TIP 2 250 TO FRONT OF DIFFUSER 1 500 TO OF GAS ORIFICE HOLES FIGURE 5 2 Firing Head Assembly Dual Manifold FRONT OF DIFFUSER TO NOZZLE TIP 2 1 4 TO FRONT OF DIFFUSER 1 1 2 TO OF GAS ORIFICE HOLES FIGURE 5 3 Firing Head Assembly D378 amp 420 IC 790 revised 2010 5 3 D LND Series Manual Maintenance INDUSTRIAL COMBUSTION 5 5 Pilot and Ignition Electrode The ignition transformer requires little attention other than making sure the ignition wire is firmly attached to the transformer and the electrode D 42 THRU 336 GAP 1 8 D 378 AND 420 GAP 3 32 LARGE PILOT SHOWN ADJUSTMENT IS SAME FOR ALL PILOT ELECTRODES FIGURE 5 4 Ignition Pilot Electrode Setting Be sure the wire insulation is in good condition and not grounded Failure to keep the ignition electrode clean and properly set can cause faulty operation The pilot assembly is supported by a socket in the diffuser and gas inlet tube No adjustment is required except prope
81. ectrical spark interference test must be performed after final adjustment See Section 3 8 IC 790 revised 2010 D LND 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 instal lation to assure maximum operating efficiency Prior to placing the boiler into initial service a complete inspection should be made of all controls connecting piping wiring and all fastenings such as nuts bolts and setscrews to be sure that no damage or mis adjust ments occurred during shipping and installation A combustion efficiency analysis made during the initial startup will help to determine what additional adjust ments are required in a particular installation 4 2 Combustion Adjustment on 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 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 0 and carbon monoxide CO 4 2 1 Stack Temperature Net stack temperature is obtained by subtracting the ambient tem
82. ed and at scheduled intervals in the maintenance program Refer to adjustment procedures and maintenance instructions given in 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 2 At the end of the post purge the blower motor is de energized The programmer returns to its starting position and stops the unit is ready to restart Abnormal shutdown might result from motor overload flame outage low water current or fuel supply interrup tion combustion or atomizing air pressure below minimum level tripped circuit breakers blown fuses or other interlock devices Check for cause and correct 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 non recycling interlock circuit any interruption in this circuit dur IC 790 revised 2010 3 7 D LND Series Manual INDUSTRIAL COMBUSTION Operation ing the pre purge or firing cycle will cause a safety shutdown This type of shutdown requires manual reset of the programming control and must be corrected before operation can be resumed 3 2 for additional information A Warning An ultraviolet flame sensor el
83. egulator 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 man ufacturer s literature for regulator adjustment 4 4 5 Low Gas Pressure Switch Turn the 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 790 revised 2010 4 3 D LND Series Manual Adjustments INDUSTRIAL COMBUSTION 4 4 6 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 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 the gas pressure to drop and press the manual reset button 4 4 7 Gas Combustion Adjustment After
84. emove the flame safeguard control and store in a dry atmosphere 5 10 IC 790 revised 2010 D LND Series Manual 5 15 Maintenance Flow Chart Recommended Test Schedule INDUSTRIAL COMBUSTION 5 15 Maintenance Flow Chart Recommended Test Schedule Item Service By Remarks DAILY Gauges Monitors Indicators Operator Make visual inspection and record readings in log Instrument and Eguipment Settings Operator Make visual check against recommended specifications Low Water Fuel Cutoff Alarms Operator Refer to instructions 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 Strength Controls Operator Read and log the flame signal for both pilot and main flame Notify Service if readings are very high very low or fluctuating 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 Pressure Interlocks Operator Refer to instruction
85. ence of dirt in the oil and in time this will result in excessive clearances which reduces the pump capacity If the oil metering pump fails to deliver capacity or meters erratically replace the oil and air pump as a unit and return the old pump for repair or exchange where allowed 4 5 2 Atomizing Air Pressure Atomizing air in the air oil tank is regulated by adjusting the valve in the return air line on integral metering units or in the air inlet on air compressor module burners The air pressure is indicated by the pressure gauge at the air oil tank A minimum of 10 psi air pressure in low fire is suggested As the firing rate increases the air pressure also increases Air pressure will be less with light oils If any change in atomizing air pressure is made check ignition several times for reliable light off Adjustments should be set to obtain reliable ignition with best low and high fire combustion results If the required atomizing air pressure cannot be maintained a lack of lubricating oil may be the cause or the intake filter may be dirty 4 5 3 Atomizing Air Proving Switch The knurled nut between the switch and bellows is turned in to raise the pressure setting The minimum amount of atomizing air is during pre and post purge during pre purge adjust the switch until it breaks the circuit Readjust the switch above this circuit break point to actuate under a condition of minimum pressure but not so close as to cause
86. ened completes the connection between the sub base and chassis contacts Press the manual reset button to be sure safety switch contacts are closed Check the control linkage for proper movement of the air volume damper and fuel meter ing components This can be done by loosening the linkage at the actuator level and manipulating it by hand Check the air shutter and adjust the low fire setting IC 790 revised 2010 D LND Series Manual Operation INDUSTRIAL COMBUSTION Component Description Boiler Check the boiler water level Be sure all boiler valves are installed correctly and posi tioned properly Set the high limit control slightly above the desired temperature Set modulating controls at the desired temperature or pressure Firing Preparations for Prior to initial firing oil flow pressure and temperature should be verified Oil Burners Inspect the compressor lube oil sump level Add oil to bring the oil level to the midpoint or slightly higher in the reservoir sight glass Make certain that the drive belts or couplings are aligned and properly adjusted To verify air flow and pressure momentarily flip the switch ON and immediately turn it OFF The programmer will continue through its cycle however without ignition or ener gizing the fuel valves Observe the air pressure gauge With the compressor running and no oil flow the pressure should be approximately 10 PSI The schematic flow d
87. er Motor MTG 2 1 4 O D X 1 2 I D X 1 8 THK 4 4 4 9 836 366 Switch Air Pressure 1 1 1 1 1 10 85 878 Support Assembly Damper to Motor P S amp P 1 1 11 152 18 Pad Motor Support 1 3 4 Wide X 6 LG X 1 8 THK 4 4 4 4 12 265 26 Cone Assembly Stator 1 265 25 Cone Assembly Stator 1 1 1 265 135 Cone Assembly Stator 1 13 19 520 Cover Access Fan Housing 1 1 14 914 205 Ring Retaining Ext Snap 2 2 2 2 2 15 56 276 Pin Hinge 1 52 278 Pin Hinge 1 1 1 1 16 835 001 Insert Coil 8 8 8 8 8 17 43 13 Latch Toggle Clamp 2 2 2 2 2 18 40 257 Housing Assembly Fan 1 40 264 Housing Assembly Fan 1 1 40 383 Housing Assembly Fan 1 40 144 Housing Assembly Fan 1 19 32 1060 Gasket Fan Housing Seal 1 1 1 1 1 252P IC 790 revised 2010 9 11 D LND Series Manual USTRIAL IN COMBUSTION 9 4 5 Blower Housing Assembly D378 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Blower Housing Assemblies Ouantity Item Part No Description 378 420 No 1 894 1368 Blower Motor 1 1 2 515 16 Seal Plate 1 1 3 85 813 Shroud Assembly Air Hood 1 1 4 85 891 Support Motor and Air Damper 1 1 5 91 Spacer varies 1 T 6 192 327 Impeller Assembly 1 1 7 869 185 Nut Hex Lock 1 3 8 12 UNF 1 1 8 152 17 Pad Blower Motor Mounting 1 1 9 836 336 Switch Air Pressure 1 1 10 85 892 Support Assembly Damper to Motor 1 1 11 152 1
88. er Support 1 1 8 1041 Bracket Assembly Drawer Support 1 13 48 141 Gas Pilot Assembly 1 1 1 14 826 40 As Required 1 1 1 15 848 166 Connector Ignition Cable Straight 1 1 1 16 873 93 Electrode Assembly Ignition W Bushing 1 1 1 IC 790 revised 2010 9 31 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 15 Drawer Assembly D175 336 9 32 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Drawer Assemblies Ouantity Item Part No Description 175 210 252 300 315 336 No 1 106 101 Block Oil Air inlet Manifold 1 1 1 1 1 1 2 853 613 O Ring 5 8 O D X 3 32 Thk 1 1 1 1 1 1 3 90 241 Tube Assembly Oil Nozzle Deliver 1 1 1 1 1 1 4 817 Varies 1 1 1 1 1 1 5 90 339 Tube Scanner Sight 9 1 1 1 1 1 1 6 928 44 Clamp Conduit 1 2 1 1 1 1 1 1 7 277 107 Nozzle Body Assembly 2 12 Nozzle Body Thds All Models 1 1 1 1 1 1 8 82 121 Spring Nozzle Compression 49 64 F L X 7 1 0 X 1 All Models 1 1 1 1 1 1 9 528 26 Nozzle Assembly All Models 1 1 1 528 30 Nozzle Assembly All Models 1 1 1 10 275 190 Diffuser Assembly Air Standard All Models 1 275 189 Diffuser Assembly Air Standard All Models 1 275 169 Diffuser Assembly Air Standard All Models 1 275 188 Diffuser Assembly Air Standard All Models 1 1 275 446 Diffuser A
89. er will proceed to the main flame position Allow the burner to operate in low fire to warm the boiler before moving to high fire Typically for No 2 through No 4 oil CO is 8 to 11 and No 5 and No 6 oil is 8 to 13 at low fire 6 Turn the manual potentiometer switch to the high fire position Check high fire combustion at this point Do not disturb previously established low fire adjustment Allow the burner to return to low fire position before adjusting high or intermediate settings The primary atomizing air pressure will increase automatically with the oil flow rate Typically for No 2 through No 4 oil CO is 10 to 13 and No 5 and No 6 oil is 11 to 15 at high fire 7 When conditions covered above are assured refer to sections 3 9 and 3 10 3 9 Normal Operation Normal operation must be with the MANUAL AUTO switch 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 program mer used During the run cycle burner input is regulated to the load demand by the modulating pressure or temperature control on the boiler The burner will continue to modulate until the operating pressure or temperature is reached Programmer control operation should be tested when the burner is initially placed into service when a control is replac
90. erify safety shutdown with a safety lockout upon failure to ignite the pilot or the main flame and upon loss of flame Each of these condi tions should be checked on a scheduled basis The safety check procedures are contained in the manufacturer s bulletin 5 3 Impeller and Stator Cone Proper clearance between the impeller and the inlet housing and between the impeller and stator cone is not critical and is set at 1 8 nominal When installing or Motor Support removing the impeller it is mandatory to use an impact lt t 1 8 Nominal wrench Gap Fabricated NOTE Under no circumstance should anything other A impeller than an impact wrench be used Inserting a bar through the impeller blade and using it as a lever will only damage the blade and also void the 5 f Motor Shat year impeller warranty If the impeller is changed to a dif Spacer Here to J Wilmpeller ferent width the stator cone position may require adjust Maintain Gap Look Nut c ment This is provided for by means of slotted mounting holes in the blast tube Loosen the three screws to repo sition the cone FIGURE 5 1 Impeller and Stator Cone 5 4 Firing Head Inspection 1 Disconnect the damper linkage 2 Release the impeller housing latch and swing the housing open for access to the firing head 3 Inspect the flame scanner lens to be sure it is clean and the support tube is in proper position to sight the flam
91. ermined by circulating rate not burner capacity Install the pump as close to the supply tanks as possible Suction lift should be as low as possible Maximum suction of 15 Hg vacuum is good practice for either light or heated heavy oil The strainer should be installed in the suc tion line just ahead of the circulating pump to prevent foreign material from entering the pump Locate the strainer so it may be easily cleaned 2 9 Oil Loop Heater This heater should heat the fuel oil for proper burning at full firing rate The proper oil temperature is that which gives the best results with the particular oil being fired This may vary widely with different fuels in different firing systems Residual oil viscosity can vary widely within grade limits and is not always within the specified limits of the grade Fuel viscosity requirements for air atomizing burners are not critical Under typical circumstances a viscosity of 100 SSU might be optimum but good results may be obtained up to 150 SSU There is no advan tage to less than 100 SSU Where the burning characteristics of the fuel are unknown the following may be considered as typical No 4 802 1252F No 5L 1159 1609F No 5H 1459 180 F No 6 1802 220 F 2 10 Burner Mounted Trim Heater An auxiliary trim heater is in line between the metering pump and 3 way oil valve The auxiliary trim heater is used for topping off oil temperature prior delivery to the nozzle 2 11
92. ermit flow 4 As the system becomes warm the pressure required for circulation will gradually drop When the return is warm open No 2 valve and throttle the flow in the bypass line with valve No 1 This will cause the oil to flow through the back pressure valve to the tank via the return line The pressure in this loop around the burner should not exceed 25 PSI When the loop around the burner becomes warm gradually close valve No 1 in the bypass line All supply oil will then flow through the burner loop 3 1 2 Oil Pressure The system pressure is regulated by the back pressure valve This should be set between 10 to 15 PSI DL amp DM Models or 12 to 20 PSI DE Models at the burner inlet after the temperature stabilizes 3 1 3 Oil Temperature Heavy oil flow and burning characteristics are dependent on oil viscosity which in turn requires temperature reg ulation A loop heater in the supply line between the circulating pump and the burner heats the oil The loop 3 2 IC 790 revised 2010 D LND Series Manual 3 2 Electrical Interference Test INDUSTRIAL COMBUSTION heater should be adjusted to give the designed operating temperature Where the burning characteristics of the fuel are unknown the following may be considered as typical No 4 802 1252F No 5L 1152 1602 F No 5H 1452 1802 F No 6 1802 220 F 3 1 4 Air Oil Tank Lube Oil Check the lube oil level in the air oil tank Inspect oil level
93. ery month to ensure smooth operation of the cam assembly Regular automotive bearing grease should be used 5 10 Burner Mounting Inspection The seal between the burner flange and furnace front plate must not permit combustion gases to escape Peri odic inspection is important Replace the gasket if necessary Inspect the burner head for signs of discoloration A change in the head color paint might indicate gas leakage between the dry oven and the boiler refractory If leakage occurs refer to Chapter 2 Section 2 4 for proper sealing procedure 5 6 IC 790 revised 2010 D LND Series Manual 5 11 Fuel Oil System INDUSTRIAL COMBUSTION 5 11 Fuel Oil System 5 11 1 Fuel Oil Circulating Pump Failure or the circulating pump to deliver sufficient oil may be due to one of the following conditions 1 Insufficient fuel oil in the storage tank 2 Suction line or check valve clogged Air leaks or air traps in the suction line Ifthe line has a high point at which an air trap can occur the line must be changed Oil strainer clogged line strainer or burner strainer Suction line piping too small Pump rotating in wrong direction Three phase pump motor operating on single phase because of fuse failure Low voltage applied to pump motor NOTE Heavy fuel oil sometimes will not leak out through a suction line joint when the burner is idle but the same joint may allow air leakage inward when a vacuum is cre
94. ft T 1 1 1 1 1 8 10 315 Bushing Oil Filter 1 1 1 1 1 1 9 843 106 Filter Oil 1 1 T 1 1 1 10 3 361 Base Assembly Compressor Set 1 1 1 1 1 1 11 809 220 Belt V B X38 1 1 1 1 1 1 12 921 527 Sheave 3 5 PD X 7 8 Bore 1B Groove 1 1 921 528 Sheave 3 85 P D X 7 8 Bore 1B Groove 1 1 1 1 13 921 524 Sheave 7 1 P D X 1 9 16 Dia 1 1 1 1 14 810 70 Bushing Split Taper 1 Bore X 1 9 16 Dia 1 1 1 1 15 74 516 Shaft Cooling Fan Mounting 1 1 1 1 1 1 16 951 174 Fan 3 Wing 12 Dia 1 1 1 1 1 1 17 39 446 Shroud Assembly Cooling Fan 1 1 1 1 1 1 18 118 749 Nameplate 1 1 1 1 1 1 19 39 446 Shroud Assembly Fan Enclosure 1 1 1 1 20 17 193 Coil Lube Oil Cooling 1 1 1 1 21 35 413 Guard Assembly Radiator 1 1 1 1 22 851 180 Glass Sight Oil Level 6 Centres 1 1 1 1 23 195 261 Tank Assembly Oil Air 1175 Cu In 1 1 1 1 1 1 24 850 3 Gauge Pressure 0 60 PSI 2 5 Dial 1 4 NPT 1 1 1 1 1 1 25 832 925 Sensor Oil Low Lube optional 1 1 1 1 1 1 26 940 659 1 4 Oil Valves 2 Way N C 1 1 1 1 1 1 27 900 676 Filter Compressor Pipe 1 1 1 1 1 1 28 171 104 Filter Basket 1 1 1 1 1 1 29 13 251 1 1 2 NPT Pipe Cap 1 1 1 1 1 1 30 59 1473 Plate Tank Mounting 1 1 1 1 1 1 IC 790 revised 2010 9 17 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 8 Compressor Set D378 420 9 18 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION
95. g control oly Bl WwW N Binding or loose linkages cams setscrews etc 6 4 IC 790 revised 2010 D LND Series Manual 6 3 Troubleshooting INDUSTRIAL COMBUSTION Problem Solution Shutdown Occurs During Firing 1 Loss or stoppage of fuel supply Defective fuel valve loose electrical connection Flame detector weak or defective Scanner lens dirty or sight tube obstructed Ol Bl N If the programmer lockout switch has not tripped check the limit circuit for an opened safety control 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 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 Orifice gate valve accidentally opened heavy oil Operate 8 Interlock device inoperative or defective 9 Air in the oil lines Bleed the lines Problem Solution Modulating Motor Does Not 1 Manual automatic switch in wrong position 2 Linkage loose or jammed 3 Motor does not drive to open or close dur
96. g the air I pressor on a burner shutdown The air purge line fo T is mounted and piped on the burner The air line thy Seege at o6 nd Ln H Am 6 from the compressor to the air purge line is by others v t gereent FIGURE 7 2 Air Purge System 7 4 Plant Air System The D Series burners are able to operate with a plant air system instead of the standard IC compressor In such cases the burner is supplied with an atomizing air regulating line 7 2 IC 790 revised 2010 D LND Series Manual 7 4 Plant Air System INDUSTRIAL COMBUSTION Adjust the air pressure with the regulator and fine tune with the needle valve to have 10 15 psi on low fire Refer to Chapter 4 to setup the burner FROM AIR SUPPLY WIRE TO FLAME AIR SAFEGUARD BLOWER FLOW MOTOR TERMINAL FIGURE 7 3 Plant Air System Top Loaded with Air IC 790 revised 2010 7 3 D LND Series Manual Accessories INDUSTRIAL COMBUSTION FROM AIR SUPPLY OIL PRESSURE DOWN STREAM OF OIL METERING VALVE NOZZLE PRESSURE TO TOP LOAD AIR PRESSURE REGULATING VALVE WIRE TO FLAME Se SAFEGUARD BLOWER Tm MOTOR TERMI NAL NOTE 1 AIR PRESSURE REGULATOR SHOULD HAVE TRIM KIT TO ALLOW OIL OVER REGULATOR FIGURE 7 4 Plant Air System Top Loaded with Oil 7 4 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 8 Flue Gas Recirculation 8 1
97. gt u w ke a H H A SADA N N O J N N N A OOOO 00006 A AAJ A di hh YN ARAM We W Ou A LE D ki AY D M D DH b L wawam FUEL OIL KEE LUBE VIL KES BYPASS OIL ATOMIZING AIR EEE LEE OIL AIR 1 COMPRESSOR 5 ATOMIZING AIR PRESSURE GAUGE 3 OIL PIPING 2 AIR CLEANER ATOMIZING AIR PRESSURE ADJ VALVE 10 NOZZLE LINE HEATER 3 STRAINER 7 TANK FILLER No 4 TO 6 OIL ONLY 4 OIL AIR TANK B OIL METERING PUMP 11 BURNER NOZZLE 12 SIGHT GLASS FIGURE 1 9 Compressor Module and Burner Oil Flow 1 9 Gas System Gas is introduced into the combustion zone from a circular manifold through multiple ports in the manifold Fir ing 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 an adjustable linkage from the modulating motor Depending upon specific requirements one or two safety shutoff motorized main gas valves are provided for installation in the gas train upstream of the butterfly valve Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating sequence 1 10 IC 790 revised 2010 D LND Series Manual 1 9 Gas System INDUSTRIAL COMBUSTI
98. his is set to pre vent the burner from starting until proper oil temperature is attained Set it below the oil thermostat setting If the cold oil interlock is set higher than the oil temperature the burner will not run 4 Replace the cover Pointer Knurled Knob FIGURE 4 2 Pointer and Knob 4 6 Linkage Modulating Motor 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 move ment of the air and fuel control devices provide proper fuel air ratios through the firing range In linkage adjust ments several important factors serve as guides e The modulating motor must be able to complete its full travel range Restrictions will damage the motor and or the linkage Lever and rod adjustments should be made with the motor in the low fire position IC 790 revised 2010 4 7 D LND Series Manual Adjustments INDUSTRIAL COMBUSTION GAS BUTTERFLY VALVE MODULATING MOTOR SLIGHTLY OPEN IN EACH CORNER AT THE LOW FIRE POSITION x COMBUSTION AIR DAMPER FIGURE 4 3 Low Fire Position COMBUSTION AIR DAMPER FUEL OIL METERING PUMP FIGURE 4 4 High Fire Position The modulating motor will be stopped at the end of its stroke by an internal limit switch Combustion gas analy sis indicates the air to fuel ratio and the degree of complete c
99. iagrams in Chapter 1 indicate the flow of fuel and atomizing air If the burner is a duel fuel model make certain that the main gas shut off cock is closed and the fuel selector switch is set to OIL 3 1 1 Oil Flow Light Oil Refer to the piping diagrams Open all valves in the oil suction and return lines The burner oil meter ing units are not capable of creating suction Fuel oil must be supplied to the metering unit at a nominal 10 to 15 PSI pressure by a circulating supply pump Heavy Oil Refer to the piping diagrams for burners using heavy oil Note the bypass valve between the supply and return lines At initial system startup or after prolonged shutdown start the system as follows 1 A vacuum or compound pressure vacuum gauge should be installed in the oil suction line and its reading noted This gauge indicates the tightness of the suction system 2 Open valve No 1 in the bypass line and close valve No 2 in the supply line to the metering pump 3 Turn on the pre heater and the circulating pump Oil will circulate from the tank through the circulating pump and pre heater returning to the tank through the bypass and return lines Observe the oil supply pressure gauge for indication that oil flow is established If no pressure shows after a few moments and the vacuum gauge shows little or no suction stop the circulating pump and re prime heavy oil in the storage tank hot well must be warm enough to p
100. in solvent and blowing it dry with compressed air Light oil strainers should be cleaned each month Heavy oil strainers should be checked and cleaned as often as the experience indicates the necessity 5 12 Gas System 5 12 1 Motorized Main Gas Valves Should the valve fail to operate check for voltage at the valve Make certain that the main shutoff cock is closed prior to testing The actuator is not field repairable nor should it be disassembled Replace the actuator if the valve fails to operate After replacement cycle the valve with the fuel shutoff to determine that it opens and closes If the valve has a visual indicator observe its position for correct operation N Caution All power must be disconnected before servicing the valves 5 12 2 Solenoid Valves A slight hum from the solenoid is normal when the coil is energized Should the valve fail to operate check that there is voltage at the valve coil If there is no voltage at the coil check for loose wiring connections If there is proper voltage at the valve coil and the valve still fails to open replace the coil Refer to the manufacturer s bul letin for correct 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 body IC 790 revised 2010 5 9 D LND Series Manual Maintenance INDUSTRIAL COMBUSTION Test for gas leaks and check the v
101. ing pre purge or close on burner shutdown a Motor defective b Loose electrical connection c Damper motor transformer defective 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 790 revised 2010 D LND Series Manual 6 5 e s D G o 2 g G o A p ION Troubleshooting 6 6 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION Accesson es 7 1 Overview The D Series burners are available with a wide selection of accessories This section will cover some of the most popular accessories 7 2 Steam Atomizing System CAPACITY ADJUSTMENT NOTES FOR INSTALLATION BURNER e 1 BY SETTING UP EITHER THE METERING BLAST TUBE ATUMIZING 1 DO NOT CLOSE 8 VALVE BETWEEN ORIFICE DR THE DIFFERENTIAL PRESSURE AIR PROVING COMPRESSOR AND NOZZLE IF COMPRESSOR 2 INCREASING PRESSURE DR OPENING ORIFICE THERE BY INCREASING VOLUME SYSTEM COMPONENTS SWITCH 15 IN OPERATION STEAM LINE PIPING TO BE LOWER Sd THAN COMPRESSOR d BUTTERFLY SHUT OFF VALVES 7 UL LISTED BUTTERBALL 8 DIFFERENTIAL PRESSURE REGULATOR ADJUSTARLE METERING ORIFICE VALVE 0 5 Tear STEAM SOLENOID VALVE WIRED TO FLAME SAFEGUARD BLOWER M
102. ion is corrected Repeat several times 4 5 Oil System 4 5 1 Oil Metering System Fuel oil supply to the integral metering unit must be at 10 psi to 15 psi and up to 20 psi on separate metering units The oil spray should ignite as soon as the oil solenoid valve opens If the oil spray fails to ignite move the metering unit adjustment lever a few degrees counterclockwise This increases the amount of oil at low fire and makes ignition easier it will also increase the oil on high fire so this must be checked later Once adjusted the pump should operate with a minimum amount of adjustment If a burner failure is caused by the oil metering pump check the following 1 See that the oil tanks are not empty IC 790 revised 2010 4 5 D LND Series Manual Adjustments INDUSTRIAL COMBUSTION That all oil valves between the burner and the tank are open That the suction line is not airbound That the low fire setting has not been disturbed That there is pressure at the integral metering unit but not to exceed 15 psi 20 psi on a separate metering unit 6 That the pump turns freely 7 Check for a clogged strainer at the suction side of the circulating pump 8 9 Check for a dirty burner strainer Check for a plugged or carboned nozzle This will show up as excessive primary air pressure 10 That the oil bypass valve is not bypassing the metered fuel oil Internal wear of the pump may take place due to the pres
103. ions Fuel oil piping and gas piping instructions are described in this chapter 2 2 Combustion Chamber Construction The combustion chamber dimensions should be proportioned to the heating load of the boiler see Figures 2 1 and 2 2 IC 790 revised 2010 2 1 D LND Series Manual Introduction INDUST COM BUSTION FIGURE 2 1 Recommended Scotch Marine Chamber Dimensions 2 2 IC 790 revised 2010 D LND Series Manual 2 2 Combustion Chamber Construction INDUSTRIAL COMBUSTION 150888888 oc eo Z COMBUSTION CHAMBER Cas CS for w x nm ox _ 9 d o om sm T _ For Installation of Furnished Refractory See Fig 2 amp 3 can be Lowered or Pitted to Obtain Dimension C For Support of Burner During Installation or Removal RECOMMENDED COMBUSTION CHAMBER DIMENSIONS FOR FIREBOX AND WATERTUBE BOILERS FIGURE 2 2 Recommended Firebox amp Watertube Boiler Chamber Dimensions IC 790 revised 2010 2 3 D LND Series Manual Introduction INDUSTRIAL COMBUSTION 2 3 Installation Locate the burner properly The burner is designed for operation with the blast tube level Do not tilt the burner up or excessively downward Installation of the refractory oven or combustion cone shipped with the burner is shown in Figures 2 3 and 2 4 2 1 INSULATING BLANKET KAO WOOL CERABLANKET DURABLANKET 2 BLOCK INSULATION FIREBRIC
104. ircuit 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 Failure to do so may result in boiler damage and or serious personal injury or death 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 il 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 follow these instructions could result in serious personal injury or death 6 2 Emergency Shutdown 1 In case of an emergency shut down the burner by turning the ON OFF switch to the OFF position Turn the fuel selector switch to the OFF position Shut off the main manual fuel shutoff valves on the fuel supply line The unit can also be shut
105. l Arm 12 LG 1 1 1 1 1 1 1 1 1 5 2 141 Arm Linkage 3 4 Shaft 7 Holes 1 1 1 1 1 1 2 259 Arm Linkage 3 4 Shaft 6 Holes 1 1 1 6 82 153 Spring Roller Guide Cam 1 1 1 1 1 1 1 1 1 1 7 36 111 Guide Cam Spring 16 16 16 16 16 16 16 16 16 16 8 71 24 Screw Spring Fastener 2 2 2 2 2 2 2 2 2 2 9 860 301 Screw Locking Set Kit 16 per kit 1 1 1 1 1 1 1 1 1 10 860 299 Screw Set 10 32 X 1 LG Half Dog Point 16 16 16 16 16 16 16 16 16 16 11 313 14 Cam Assembly Left Hand 1 1 1 1 1 1 1 1 1 1 313 15 Cam Assembly Right Hand 2 2 2 2 2 2 2 2 2 2 12 476 84 Linkage Cam Follower Assembly Gas 1 1 1 1 1 1 1 1 1 1 476 82 Linkage Cam Follower Assembly Oil 1 1 1 1 1 1 1 1 1 13 2 13 Arm Linkage 5 16 Shaft 17 Holes 1 1 1 1 1 1 1 1 1 1 14 69 303 Roller Guide Assembly 2 2 2 2 2 2 2 2 2 2 15 8 1356 Bracket Linkage Arm Mounting 2 2 2 2 2 2 2 2 2 2 16 74 504 Shaft Linkage Arm Mounting Single Spring Gas 1 1 1 1 1 1 1 1 1 1 74 506 Shaft Linkage Arm Mounting Double Spring Oil 1 1 1 1 1 1 1 1 1 1 17 807 339 Bearing Nylon 3 8 1 D 2 2 2 2 2 2 2 2 2 2 18 82 140 Spring Cam Assembly Return Gas 1 1 1 1 1 1 1 1 1 1 82 155 Spring Cam Assembly Return Oil 1 1 1 1 1 1 1 1 1 1 19 10 307 Bushing Mod Motor Control Arm 22 LG 1 1 1 1 1 1 1 10 343 Bushing Mod Motor Control Arm 34 11 16 LG 1 1 1 IC 790 revised 2010 9 53 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION
106. l metering pump in the field Any attempt will void the warranty or the exchange policy Whenever an oil metering pump fails to deliver full capacity or pressure order a replacement pump at once and return the old pump for repair or exchange where allowed IC 790 revised 2010 5 7 D LND Series Manual Maintenance INDUSTRIAL COMBUSTION 5 11 3 Primary Air Pump or Compressor The air compressor itself reguires little maintenance however its life is dependent upon sufficient clean cool lubricating oil The oil level in the air oil tank must be checked regularly Lack of oil will damage the compressor Disassembly or field repairs to the air compressor are not recommended Check the air oil tank sight glass for proper oil level The level should be kept at the midpoint of the sight glass The compressor rotor must turn freely All tube connections must be air tight N Caution Do not attempt field repair of the compressor Installation of a new compressor is mandatory Send the old compres sor in for repair or exchange where allowed Alignment of the compressor and motor sheaves and proper belt tension are important Belt tension is adjusted according to the displacement of the belt with thumb pressure The displacement should be 3 8 to 1 2 To adjust loosen the two bolts on the compressor mounting flange and the three setscrews which hold the com pressor in place The mounting f
107. lange is slotted at the top which permits belt tightening If the slot in the mounting flange is insufficient for obtaining proper belt tension the modular base has two extra holes for this purpose Move the top bolt to the next hole and adjust Tighten bolts and setscrews Replace the belt guards If the belt becomes frayed or cracked replace it 5 11 4 Air Cleaner Never operate the compressor without the air cleaner in place The cleaner should be cleaned at regular inter vals The correct oil level must be maintained in the air cleaner Use the same oil used for air compressor lubri cation 5 11 5 Air Oil Tank Check the lube oil level in the air oil tank Inspect oil level regularly as loss of oil will damage the compressor Change oil every 2000 hours of operation The air oil tank should be drained once a year and thoroughly flushed Remove the mist eliminator pads from the upper section of the tank wash thoroughly in kerosene and dry Refill with non detergent SAE30 oil to a level midway up the sight glass For normal environment use SAE30 oil For a 32 2F and below environment use SAE 10 oil 5 11 6 Oil Level Sight Gauge The oil level sight gauge can be cleaned by removing it from the air oil tank and soaking it in a detergent solu tion If cleaning the gauge proves unsatisfactory replace it 5 11 7 Compressor Oil Filter Lube Oil Strainer The lube oil strainer prevents foreign materials from entering the co
108. le Assembly 1 5 1 8 3 Burner Mounted Trim Heater 1 6 1 8 4 Oil Strainer 1 6 1 8 5 Atomizing Air Proving Switch 1 6 1 8 6 Air Lube Oil Tank 1 6 1 8 7 Integral Air Oil Unit 1 6 1 8 9 AirCompressor 1 7 1 8 10 Oil Metering 1 7 1 8 11 Separate Compressor Module 1 7 1 9 Gas System 1 10 1 9 1 Main Gas Train Components 1 11 1 9 2 Pilot Gas Train Components 1 12 1 9 3 Operation 1 12 Introduction 2 1 2 1 Application 2 1 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION 2 2 Combustion Chamber Construction 2 1 2 3 Installation 2 4 2 4 Packing Plastic Refractory Around Oven 2 5 2 5 Separate Compressor Module 2 5 2 6 Typical Oil Supply Loop 2 6 2 7 Oil Circulating Loop Operation 2 7 2 8 Circulating Oil Pump 2 8 2 9 Oil Loop Heater 2 8 2 10 Burner Mounted Trim Heater 2 8 2 11 Back Pressure Valve 2 8 2 12 Gas Piping 2 9 2 13 Installation Checklist 2 9 CHAPTER 3 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 Oil Temperature 3 2 3 1 4 Air Oil Tank Lube Oil 3 3 3 1 5 Firing Preparations for Gas Burners 3 3 3 2 Electrical Interference Test 3 3 3 2 1 Gas Fired 3 3 3 2 2 Oil Fired 3 3 3 3 Gas Pilot Flame Adjustment 3 4 ii IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 4 3 4 Startup
109. losed 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 1 12 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION Pee Introduction 2 1 Application Electrical power available is usually 208 volt 3 phase 60 cycle 230 460 volt 3 phase 60 cycle or 380 volt 3 phase 50 cycle The control circuit is 115 volt single phase 60 cycle or 115 volt single phase 50 cycle Refer to the electrical schematic diagram shipped with the burner Power connections are made at the control panel Wiring from the panel to burner mounted components is installed at the factory Wiring from the burner panel to boiler controls low water controls remote compressor motor and remotely located fuel valves is fur nished by the installer Automatic over fire draft control or barometric draft regulators are not usually required except where the system has a tall chimney The exact height of a chimney requiring draft control is indeterminate but draft regulation is seldom needed for chimneys less than fifty feet high especially with Scotch Marine or sealed firebox boilers Fuel requirements for burners of all sizes are listed in the specificat
110. mage and cracks in the refractory 2 10 IC 790 revised 2010 D LND Series Manual 2 13 Installation Checklist INDUSTRIAL COMBUSTION BACK PRESSURE VALVE SET AT 10 15 PSI 2 WAY VALVE ON BURNER TO DRAWER ASSEMBLY RELIEF VALVE REQUIRED IF PUMP DOES NOT PRESSURE LOWOIL HAVE AN INTERNAL RELIEF GAUGE amp PRESSURE RELIEF VALVE SET AT 50 PSI NEEDLE SWITCH VALVE PIPING BY OTHERS PIPING BY L C NO 2 OIL RECOMMENDED PIPE SIZE TANK TO CIRCULATING PUMP CIRC OIL PUMP TO BURNER amp RETURN DL LNDL 42 5463 84 nd DLLNDL 42 54 63 84 THIS PIPING LAYOUT IS FOR REFERENCE ONLY AND IS SUBJECT TO CHANGE WITHOUT NOTICE OPTIONAL EQUIPMENT MAY CHANGE THIS LAYOUT FIGURE 2 7 Recommended Pipe Size IC 790 revised 2010 2 11 D LND Series Manual INDUSTRIAL COMBUSTION Introduction BACK PRESSURE VALVE SET AT 10 15 PSI 2 WAY VALVE ON BURNER arenis AE co pes ae aaa 3 WAY VALVE i ON BURNER RELIEF 1 VALVE l CHECK VALVE Kate 2 PRESSURE kami REQUIRED IF PUMP DOES NOT GAUGE amp HAVE AN INTERNAL RELIEF NEEDLE RELIEFVALVESETAT 50 PSI VALVE OIL METERING i PUMP SUPPLIED I VACUUM 1 Ud MEARS GAUGE H VALVE ff P 3 A E KO g t WI CH RG STRAINER s z STRAINER VALVE gt GATE E 3 VALVE OIL OIL AG C
111. ment is to be issued 2 Once an RGA number has been issued the item may be returned You will have thirty 30 days from the RGA date of issue to return the item After the thirty days there will be a 10 handling charge 3 Returned goods must have the RGA number appearing on the address label attached to the outside of the box being returned If the RGA number is not on the label your credit may be delayed and there will be a 50 00 service charge for paperwork All new parts returned to the factory will be charged with a 25 restocking fee Please Note Failure to provide complete and correct information may result in delayed or credit refusal Return of warranty parts Warranty parts must be returned to the factory freight prepaid within thirty 30 days after a new part has been received or there will be a 10 handling charge Shipping charges On a warranty part we will assume standard shipping charges This does not include special handling such as air freight U P S Next Day Air Service or U P S Second Day Air Service etc Motor Warranty Policy The following procedure must be used for proper replacement and or repair of electric motors that have failed under warranty 9 2 IC 790 revised 2010 D LND Series Manual 9 3 Return Goods Procedures Credit or Replacement Parts INDUSTRIAL COMBUSTION 1 Remove the motor from the unit and take the motor to a Manufacturer Authorized Service Station 2 The Service St
112. mp Air Damper 1 1 1 1 1 85 815 Support Motor amp Air Damper 1 1 4 91 Spacer varies 5 192 302 Impeller Assembly 13 1 2 O D X 1 7 32 Wide X 1 1 4 Shaft S S 192 301 Impeller Assembly 15 O D X 1 1 32 Wide X 1 1 4 Shaft p 192 300 Impeller Assembly 16 O D X 1 21 32 Wide X 1 1 4 Shaft S 192 305 Impeller Assembly 16 O D X 1 1 32 Wide X 1 1 4 Shaft S amp P S 192 314 Impeller Assembly 18 O D X 11 16 Wide X 1 1 4 Shaft P 192 313 Impeller Assembly 19 1 8 O D X 1 1 32 Wide X 1 1 4 Shaft P p 192 304 Impeller Assembly 19 1 4 O D X 1 7 32 Wide X 1 3 4 Shaft P S 192 310 Impeller Assembly 20 O D X 1 19 32 Wide X 1 3 8 Shaft S 192 303 Impeller Assembly 21 O D X 1 3 32 Wide X 1 3 8 Shaft P 192 309 Impeller Assembly 21 O D X 1 1 2 Wide X 1 3 8 Shaft P 192 312 Impeller Assembly 21 O D X 2 1 32 Wide X 1 3 8 Shaft S 192 311 Impeller Assembly 23 O D X 1 13 16 Wide X 1 3 8 Shaft P 6 869 119 Nut Hex Lock 1 14 UNF 1 1 1 1 1 869 145 Nut Hex Lock 1 1 4 12 UNF 1 1 7 914 205 Ring Retaining Ext Snap 2 2 2 2 2 2 2 8 56 272 Pin Hinge 1 1 1 56 275 Pin Hinge 1 1 9 836 366 Switch Air Pressure 1 1 1 1 1 1 1 10 865 28 Knob Blower Housing Latch 1 1 1 1 1 1 1 11 43 10 Latch Assembly 1 1 1 1 1 1 1 12 265 21 Cone Assembly Stator 1 1 1 265 24 Cone Assembly Stator 1 1 265 22 Cone Assembly Stator 1 265 27 Cone Assembly
113. mpressor The strainer screen must be cleaned at regular intervals The screen is easily removed for cleaning by unscrewing the bottom plug Immerse in solvent and thoroughly clean 5 8 IC 790 revised 2010 D LND Series Manual 5 12 Gas System INDUSTRIAL COMBUSTION 5 11 8 Nozzle Line Heater Nozzle line heaters damaged by water accumulation do not qualify for warranty or exchange service Failure to prevent water accumulation inside the heater manifold constitutes improper care Completely drain the heater manifold periodically This should be part of the preventive maintenance program maintenance consists primarily of removing the heating element from the manifold and scraping any accumula tion of carbonized oil or sludge deposits from the heat exchange surfaces Before braking electrical connections to the heating elements mark all wires and terminals to assure correct replacement of wires Periodic cleaning is necessary to prevent overheating or burnout of the elements If operation of the heater becomes sluggish examine the elements and clean as required Inspect the manifold each time the heater is removed Flush all accumulated sludge and sediment before it is turned on 5 11 9 Oil Strainers Oil strainers should be cleaned frequently to maintain a free and full flow of fuel The strainer screen must be removed and cleaned at regular intervals The screen should be removed and cleaned thoroughly by immersing it
114. n 2 Service station will determine warranty status by installation date of unit and date of failure along with age of motor determined by date code 3 If within warranty limitations unit will be inspected for cause of failure and repair requirements Determina tion will be made that failure was caused by defect in materials or workmanship and not by misuse abuse accident or other exclusions listed in our warranty 4 If minor repair is required service station will repair motor and return to user on a no charge basis 5 If major repair rewind is required service station may A Rewind motor and return to user on a no charge basis if user requirement is not an emergency and repair can be made within Marathon Electric price guidelines or B Nameplate will be removed and along with a report of cause of failure will be given to the user e User will present nameplate and report to distributor 7 Distributor will furnish user with a new motor no charge either from his inventory or secure replacement unit direct from parent organization Marathon Electric Warranty Repair Procedure DPN 79 113 Electric Motors 48 215 Frame IC 790 revised 2010 9 3 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 Parts Lists and Drawings 9 4 2 Blast Tube Assembly D42 336 9 4 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION
115. nuisance shutdowns Since the pressure of the atomizing air is at minimum when no fuel is present at the nozzle adjustment of the switch should be made while the unit is purging but not firing 4 5 4 Low Oil Pressure Switch The low oil pressure switch is adjusted at the minimum setting of 4 psi Turning the knob clockwise will increase pressure counterclockwise will decrease pressure 4 5 5 High Oil Temperature Switch The temperature switch is set slightly below the maximum of 260 F To adjust remove cover and turn the screw located on top Clockwise will increase temperature counterclockwise will decrease temperature 4 6 IC 790 revised 2010 D LND Series Manual 4 6 Linkage Modulating Motor INDUSTRIAL COMBUSTION 4 5 6 Nozzle Line Heater NOTE Be sure the manifold is filled with oil prior to startup 1 Remove the cover that encloses the thermostat and interlock switch The pointer controls the thermostat set ting The knurled knob controls the cold oil interlock switch 2 The thermostat pointer should be set at position 6 and then raised or lowered as required Higher numbers indicate higher temperatures Let the unit run before making further adjustments The thermostat governing the nozzle line heater element is set lower than the thermostat governing the oil heater in the circulating loop 3 The cold oil interlock switch is controlled by the small brass knurled knob under the pointer T
116. ombustion The closer the rod comes to parallel 4 8 IC 790 revised 2010 D LND Series Manual 4 7 Cam Trim Adjustment INDUSTRIAL COMBUSTION with the lever the slower the rod moves The angles ofthe 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 4 7 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 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 then operate the automatic modulating cycle to assure satisfactory results Tighten the locking setscrews FUEL INPUT DECREASE DRI
117. operating for a sufficient period of time to assure a warm boiler make adjustments for most efficient com bustion 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 the manufacturer s direc tions 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 additional information NOTE Check for CO through the entire firing range 4 4 8 Secondary Valve Adjustment Gas Models D 378 amp 420 The secondary valve feeds gas to the inner spuds A slot in the valve stem in relationship to the shut open scale on the valve indicates the blade position In the low fire starting position the stem slot should be positioned at the left hand 1 4 mark and travel in a counterclockwise direction to the mid fi
118. oward the high fire position where the 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 IC 790 revised 2010 8 5 D LND Series Manual Flue Gas Recirculation INDUSTRIAL COMBUSTION INISNOH JaNHna 9NIN3dO 803 338Y3A0W3H N01123S 3dld 030NY14 LYOKS a3u1n034 Sv JAWA TOHINOS 137WI SVO NIVA wa 19000 ON did ua HINYNB 3n VASA DONT 3801 15 18 9Nidtd 8 9 4 orf HOS AMININ PS ef MOBITZ q34 SnIQvH 5N01 j SININJUINOJU 39Vd5 LINS 01 IND 9NIdld 4 9 4 Or HOS BAWA 43401nHS HD 3 ONINOTLISOd Q334H3438d 17ns38 7114 HOLON JOHLNAON IHL OL 32YMYO i4vHS HOLON GON JHL 30 STXY 3Hl AB Q3NI4330 51 _ 1V21183A A31v21183A Q31NDOM 38 LON NVI HOLON TOMANGON IHL IN0111S02 SIHL NI Q31NnOM 38 M3A3N OTAOHS JAA 4201795 4 9 4 TONTNIVM NOLAVIASNI 40 30 MAININ V HLTA 0343405 38 O3HINDIH Sv SNIdid 3 9 4 TIV LYH 03453995 S 1 1404415 ONIdId 310N NW 5301090 3S3H1 NI NOTLISOd 7Y211N3A JHL H NI O3LNNON LON SI BOLOK JOHINOON IVHl n ILON 318Y14322YNn ST NWOHS NOIIV301 03445333Hd JHL N3HM 3AT1VA 3304nHS 47974 IHL ONINOTLISO 404 3910H2 YNOILd0 B d0Z Y QN1 H d8 N1 B d9CC 0NT EASI KONT duni variat e wows 8 d S00 ON1 8
119. pendicular to the rod The closer the rod comes to being parallel with the lever the slower the rod moves Always allow the burner to return to low fire position before adjusting high or intermediate settings Do not alter low fire settings Normally the air control damper will be approximately 1 open in low fire position Excessive opening in low fire can cause pilot ignition problems Air to the pilot is supplied under pressure to compensate for variations in furnace pressure but the damper must be in low fire position for reliable ignition AWarning Keep fingers away from the air intake below the damper The damper is actuated with sufficient force to cause seri ous injury INCR GAS INCREASE BUTTERFLY DECR VALVE DECREASE NOTE LINKAGE SHOWN IN APPROX LOW FIRE POSITION HIGH FIRE FUEL OIL MODUTROL AIR INTERLOCK METERING PUMP MOTOR SWITCH E A XO ROTARY AIR ROTARY AIR n DAMPER BOX DAMPER LINKAGE AIR INTAKE FIGURE 4 6 Firing Rate Control Adjustments 4 10 IC 790 revised 2010 D LND Series Manual 4 8 Firing Rate Controls INDUSTRIAL COMBUSTION o MOTOR ROTATIONS tO CCW ROTATION CW ROTATION FACING REAR OF MOTOR FACING REAR OF MOTOR E OH AIR PUMPS OIL AIR AIR 5 5 4 4 6 5 5 4 7 5 6 4 7 6 7 4 8 6 B 4 9 6 2 3 USED ON MODELS e DL DLG 105 145 5 75 DM DMG 63 TO 145 SS 8 75 OIL ME
120. perature 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 790 revised 2010 4 1 D LND Series Manual Adjustments INDUSTRIAL COMBUSTION 4 2 2 Smoke Measurement Smoke measurements can be made using a variety of different methods The standards will vary somewhat according to the eguipment used and instructions accompanying the instrument should be followed Smoky combustion can result from e improper air delivery e insufficient draft e improper fuel viscosity e improper fuel air ratio excessive air leaks in the combustion chamber e improper fuel oil temperature 4 2 3 Gas Adjustments Low fire combustion analysis typically is 7 to 9 CO and less than 04 CO 400 ppm A high fire reading typically is 9 to 10 596 CO and less than 04 CO 4 2 4 Fuel Oil Adjustments Adjust for a clean fire Typically for No 2 through No 4 oil CO is 8 to 11 at low fire and 10 to 13 at high fire For No 5 and No 6 oil CO is 8 to 13 at low fire and 11 to 15 at high
121. r See Section 2 9 for heater operation Multiple Burners Piping Loop See Figure 2 15 at the end of this chapter for example of multiple burners piping installation IC 790 revised 2010 2 7 D LND Series Manual Introduction INDUSTRIAL COMBUSTION An oil circulating pump provides continuous oil circulation to the circulation loop A back pressure valve holds 10 to 15 PSI onthe loop system With the oil supply line connected only to the oil metering pump inlet all oil must pass through the pump During pre purge unmetered oil flows through a bypass section of the oil metering pump Metered oil passes through the metering section to a de energized 3 way oil valve common port Both unmetered and metered oil must pass through the back pressure valve and return to an oil storage tank The oil metering pump will only meter oil It will not serve as a circulating pump At trial for main flame main fuel the 3 way oil valve is energized admitting metered oil to the nozzle for atomization and fast smooth ignition Unme tered oil continues to flow through the bypass section of the oil metering pump and retums to an oil storage tank 2 8 Circulating Oil Pump A circulating oil pump is reguired to deliver fuel oil from the storage tank to the burner at a minimum of 150 of the maximum burner firing rate The excess oil allows a margin for piping error viscosity changes in the fuel oil and circulating pump wear Correct pipe sizing is det
122. r leads the gas pilot assembly air and oil tubes and the nozzle support assembly before attempting to remove the diffuser 2 Mark the diffuser s relative position to the 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 three screws holding the diffuser to the blast tube and slowly pull the diffuser along the blast tube towards the firing head Keep the diffuser as parallel as possible If it should become stuck or tight do not apply any tool which would distort the shape or blade configuration A small wooden block tapped gently against the diffuser s outer edge will help expedite its removal 4 Clean all carbon from the diffuser vanes and reinstall in reverse order of disassembly aligning the diffuser with the scribed marks Do not attempt to drive the diffuser back along the blast tube with anything other than a small block of wood tapped against the diffuser s outer edge 5 When reinstalling be sure the diffuser is centered with the proper distance as shown in Figures 5 2 and 5 3 5 9 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 NOTE It is essential that the cam spring cam follower bearing wheel and cam follower arm at the pivot point be greased sparingly ev
123. r positioning of the electrode wire 5 6 Flame Scanner The scanner must be clean Even a small amount of contamination will reduce the flame signal Wipe the scan ner lens with a clean soft cloth 5 7 Oil Nozzle Successful burner operation requires use of the proper style nozzle tip and keeping the orifice clean Standard nozzle tips furnished on the burners are of a special emulsifying type which delivers a spray of extreme fineness and at an angle which insures proper mixing with the air stream Unsatisfactory performance and loss of effi Ciency can result from the use of non standard nozzle tips If the burner flame becomes stringy or lazy it is pos sible that the nozzle spring is not properly in place or the nozzle is clogged This problem is usually indicated by an abnormally high reading on the atomizing air pressure gauge on the air oil tank To remove the nozzle 1 Disconnect the oil and air tubes from the nozzle assembly 2 Loosen the three 1 4 screws holding the nozzle spider bracket to the support ring 3 Withdraw the nozzle and bracket assembly 4 Clean the nozzle tip by unscrewing the tip from the nozzle body Use care not to distort the tube 5 4 IC 790 revised 2010 D LND Series Manual 5 7 Oil Nozzle INDUSTRIAL COMBUSTION 5 Hold the nozzle body in a vise or use two wrenches one on the body and one on the tip 6 Disassemble the nozzle tip 7 Carefully clean all parts in solvent and rea
124. re Air Interlock 1 1 1 1 5 2 184 Arm Linkage Assembly 1 1 1 1 6 807 333 Bearing Square 4 PT Damper Shaft 3 4 2 2 2 2 8 2 189 Arm Linkage Assembly High Fire Switch 1 1 1 1 IC 790 revised 2010 9 27 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 13 Drawer Assembly D42 63 9 28 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Drawer Assemblies Ouantity Item Part No Description 42 54 63 No 1 277 139 Nozzle Body Assembly 22 MM X 1 5 MM Nozzle Thds All Models Except DE DEG 1 1 1 277 105 Nozzle Body Assembly 1 1 8 16 Nozzle Thds Models DE DEG 1 1 1 2 82 33 Spring Nozzle Compression 5 FL X 5 16 1 0 X 072 All Models Except DE DEG 1 1 1 82 129 Spring Nozzle Compression 6 FL X 5 16 I D X 082 Models DE DEG 1 1 1 3 528 9 Nozzle Assembly Models DL DLG 1 1 528 13 Nozzle Assembly Models DL DLG 1 528 9 Nozzle Assembly Models DG DM DMG 1 528 13 Nozzle Assembly Models DG DM DMG 1 528 29 Nozzle Assembly Models DG DM DMG 1 528 47 Nozzle Assembly Models DE DEG 1 1 1 4 817 varies 1 1 1 5 90 228 Tube Scanner Sight 8 1 1 1 6 8 1152 Bracket Assembly Nozzle Support 1 1 1 7 48 140 Gas Pilot Assembly 1 1 1 8 275 243 Diffuser Assembly Air Standard Models DL DLG 1 275 244 Diffuser Assembly Air Standard Mo
125. re shut position Continuing in a counterclockwise direction the stem slot should stop at the right hand 1 4 mark This is the high fire position Both low and high fire positions are approximate Adjustments to the valve should be made on the secondary valve linkage arm To increase the travel move the linkage arm closer to the pivot point To decrease the travel move the linkage arm away from the pivot point The primary valve which feeds the outer spuds should be adjusted as normal 4 4 IC 790 revised 2010 D LND Series Manual 4 5 Oil System INDUSTRIAL COMBUSTION PRIMARY GAS MANIFOLD SECONDARY GAS MANIFOLD PRIMARY SECONDARY 7 VALVE SECONDARY VALVE STEM SLOT amp SCALE O sZ ROTATION FIGURE 4 1 Gas Primary and Secondary Valve Arrangement 0 378 420 4 4 9 Secondary Valve Adjustment Dual Manifold Each zone is controlled by a butterfly valve linked to a 14 point adjustment cam The primary large butterfly valve controls the main gas orifices and the secondary small butterfly valve controls the pre mix gas spuds Refer to the adjustment section to setup the burner In the low fire position the secondary valve controlling the pre mix spuds is almost closed After all adjustments are made throughout the modulating range go back and relight the burner Upon startup check that the fire is not burning behind the diffuser If this happens close the secondary valve until this situat
126. rews Before operating pumps metering heads and compressors make certain that reservoirs are properly filled with the specific lubricant Open all necessary oil shutoff valves Do not run compressors pumps or metering units without oil Before connecting electrical current to any component be sure the supply voltage is the same as that specified on component nameplates Before burner operation be sure all motors are rotating in the correct direction Before firing make sure that the refractory flame cone is properly sealed to the burner mounting flange and the boiler front plate Make certain that the operator in charge is properly instructed in the operation and maintenance procedures Caution Before opening the gas shutoff valves read the regulator instructions carefully Open the shutoff valve slowly to allow inlet pressure to build up slowly in the regulator until it is fully pressurized Opening the shutoff valve quickly will damage the regulator Do not exceed the regulator pressure ratings Caution Lubricating oil is drained from the air oil tank before shipment Before attempting to start the burner add oil to the recommended level N Caution The burner refractory cone is air cured only Heat curing must be initiated at initial startup Run the burner at low fire for a period of 6 to 8 hours before starting to gradually increase the firing rate Failure to do so will result in da
127. s Manually adjust until switch opens 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 IC 790 revised 2010 5 11 D LND Series Manual e s D G o 2 g G o A mi Le p ION Maintenance 5 12 IC 790 revised 2010 D LND Series Manual INDUSTRIAL COMBUSTION CHAPTER 6 Troubleshooting A 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 A Warning Disconnect and lockout the main power supply in order to avoid the hazard of electrical shock Failure to follow these instructions could result in serious personal injury or death 6 1 Awareness Chapter 6 assumes that e The unit in question has been properly installed and th
128. s and Drawings INDUSTRIAL COMBUSTION Blast Tube Assembly Ouantity Item Part No Description 315 336 378 420 No 1 8 1275 Bracket 28 Support Standard 2 2 2 2 Panel 2 817 Switch Pressure Air Oil 4 12 psi 1 1 1 3 40 380 Housing Assembly Firing Head 1 40 410 Housing Assembly Firing Head 1 40 402 Housing Assembly Firing Head 1 1 4 8 1018 Bracket T 1 1 1 5 836 301 Switch Safety Interlock 1 1 1 1 6 32 1127 Seal varies 1 1 1 1 7 19 488 Cover Firing Head Access 1 1 19 529 Cover Firing Head Access 1 1 8 31 36 Glass Flame Sight 1 1 9 869 184 Nut Sight Glass 1 1 1 1 10 85 187 Support Assembly Burner 1 1 1 1 IC 790 revised 2010 D LND Series Manual 9 7 INDUSTRIAL COMBUSTION 9 4 3 Blower Housing Assembly D42 175 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Blower Housing Assemblies Ouantity Item Part No Description 42 54 63 84 105 145 175 No 1 894 1200 Motor 3 HP S amp P 5 894 1237 Motor 5 HP S amp P S 894 1240 Motor 7 5 HP P S 894 1209 Motor 10 HP P 894 1245 Motor 15 HP S amp P 894 1247 Motor 20 HP S amp P 2 29 834 Flange Motor Mounting 1 1 1 29 815 Flange Motor Mounting 1 1 3 85 807 Support Motor a
129. s pressure is above a pre selected setting Should the pressure drop below this setting the switch contacts will open causing main gas valve s to close This switch reguires manual reset after being tripped HIGH GAS LOW GAS PRESSURE PRESSURE SWITCH SWITCH MAIN GAS VALVE W P O C BUTTERFLY SHUTOFF SHUTOFF VALVE COCK COCK TO CH 1 s Burner L JOE LL a I UH PILOT VALVE REGULATOR FIGURE 1 10 Gas Train Components IC 790 revised 2010 1 11 D LND Series Manual Introduction INDUSTRIAL COMBUSTION 1 9 2 Pilot Gas Train Components Component Description Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to the pilot It closes after main flame is established Gas Pressure Regulator Reduces gas pressure to that reguired by the pilot Gas Pilot Shutoff Cock For manually closing the pilot gas supply 1 9 3 Operation Metered gas flows through the main gas shutoff cock through the pressure regulator to the automatic gas valves and butterfly valve to the gas manifold The butterfly gas valve modulates flow to burner input demand The butterfly valve is positioned through mechanical linkage by the modulating motor The air control damper is positioned simultaneously by the modu lating motor The automatic gas valve s cannot be energized unless the combustion air proving switch is c
130. sis Air Oil Metering Pumps e Oil and Air Pumps e Bearing Assembly e Air Modulators e Relief Valves 9 2 Parts Shipping Policy All orders for stocked items will be processed and ready for shipment within twenty four 24 hours of its receipt Air shipments U P S or otherwise will be shipped the same day if the order is received before 2 30 P M weather permitting IC 790 revised 2010 9 1 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION Ground shipments to Wisconsin and bordering states will be shipped the same day upon reguest All parts orders and exchange parts must be sent to Industrial Combustion 351 21st Street Monroe Wisconsin 53566 Plant Phone 608 325 3141 Fax 608 325 4379 Parts Direct 608 325 5003 Fax 608 329 3190 9 3 Return Goods Procedures Credit or Replacement Parts Defective Warranty parts or parts to be repaired are not to be returned to the Parts Department without calling for a Return Goods Authorization Number 1 Before any item is returned please call the Parts Department to obtain an RGA Return Goods Authorization Number Please have the following information available when calling A Item Part Number B Description of Item C Reason for the return with a full description of the defect s D Parts Order or Sales Order on which the item was purchased E Name address and date of installation F Indicate if a credit or a replace
131. ssemble the nozzle 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 swirler 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 surer the nozzle is centered with the proper distance from the diffuser See Figures 5 2 and 5 3 NOZZLE AIR ee BODY SPRING 274 SWIRLER Ge NOZZLE TIP 1e G BRACKET TYPICAL FOR BURNER WITH INTEGRAL AIR COMPRESSOR NOTE SLEEVE MUST BE SCREWED STAMPED TIGHTLY INTO NOZZLE BODY SO THAT O RING AND SLEEVE EXTEND PROPER DISTANCE INTO MANIFOLD NOZZLE DO NOT DISTORT OR CUT O RING BODY WHEN INSERTING SLEEVE ASSEMBLY INTO MANIFOLD BORE SPRING SWIRLER SUB ASSEMBLY TYPICAL FOR BURNER e SPIDER WITH SEPARATE AIR COMPRESSOR FIGURE 5 5 Oil Nozzle Assemblies IC 790 revised 2010 5 5 D LND Series Manual Maintenance INDUSTRIAL COMBUSTION N Caution Do not attempt to use a wire or a sharp metal tool to clean the nozzle orifice as this will distort the fine orifice and ruin the nozzle Use a sharp pointed piece of soft wood 5 8 Diffuser The diffuser is factory set and does not require attention under normal operating conditions If fouled with car bon the diffuser should be removed for cleaning 1 First remove the electrode and scanne
132. ssembly Air Standard All Models 1 11 8 1095 Bracket Nozzle Support 1 1 1 1 1 1 12 8 1622 Bracket Assembly Drawer Support 1 1 1 1 1 1 13 76 109 Sleeve Inner for Drawer Assembly 1 1 1 1 1 1 14 48 141 Gas Pilot Assembly 1 1 1 1 1 1 15 826 40 As Required 1 1 1 1 1 1 16 848 166 Connector Ignition Cable Straight 1 1 1 1 1 1 17 873 93 Electrode Assembly Ignition W Bushing 1 1 1 1 1 1 IC 790 revised 2010 9 33 D LND Series Manual Parts Lists and Drawings INDUSTRIAL COMBUSTION 9 4 16 Drawer Assembly D378 420 9 34 IC 790 revised 2010 D LND Series Manual 9 4 Parts Lists and Drawings INDUSTRIAL COMBUSTION Drawer Assemblies Ouantity Item Part No Description 378 420 No 1 817 Varies 1 1 2 106 101 Block Oil Air Inlet Manifold 2 2 3 928 80 Clamp Conduit 3 4 1 1 4 8 1627 Bracket Scanner Mount 1 1 5 90 338 Tube Scanner Sight 9 1 1 6 853 613 O Ring 5 8 O D X 7 16 I D X 3 32 Thk 2 2 7 7 196 U Bolt 3 4 Pipe Thd 1 4 20 1 1 8 90 559 Tube Assembly Oil Nozzle Deliver 2 2 9 277 107 Nozzle Body Assembly 2 12 Nozzle Thds All Models 1 1 10 82 121 Spring Nozzle Compression 49 64 F L X 7 1 D X 1 2 d 11 528 49 Nozzle Assembly All Models 1 1 12 85 894 Nozzle Support Assembly 1 1 13 42 79 Spud Secondary 1 1 14 48 141 Gas Pilot Assembly 1 1 15 826 40 As Required 1 1 16 848 166 Connector
133. table linkage 1 OIL Ai PUMP ACTUATING ARM TANK CONNECTIONS 2 AR INLET FATER A ATOMIZING AIR TO BURNER NOZTLE 3 ATOMIDING AIR PRESSURE ADJUSTING VALVE 9 Om TANK PEL PLUG 4 FUEL OIL INLET 10 ATOMIZING AR BYPASS LINE OAL INLET 11 LUGE OIL OUTLET TO PUMP 6 OlL AIR DISOHARGE 12 ATOMIZING AIR TO PRIMARY AIR PRESSURE SWITCH 7 FUEL OIL DISCHARGE TO SOLENOID VALVE 13 SIGHT GLASS FIGURE 1 6 Integral Oil Air Metering System and Tank 1 8 IC 790 revised 2010 D LND Series Manual 1 8 Oil System Air Atomizing INDUSTRIAL COMBUSTION DISCHARGE FLAT ONSHAFT ATT OCLOCK INLOW FIRE POSITION FUEL OL METERED OIL INLET DISGHARGE FIGURE 1 7 Fuel Oil Metering System Used With Separate Compressor RETURN TO STORAGE TANK TO ATOMIZING gt switch mm u Een A LUBE OIL LUBE Ott E ATOMIZING Ain T OIL AIR METERING PUMP 5 AIR COOLER 2 AIR CLEANER 7 O1L AIR TANK J ATOMIZING AIR ADJ VALVE 8 ATOMIZING AIR PRESSURE GAUGE 4 NOZZLE LINE HEATER 9 TANK FILLER PLUG No 4 TO 6 OIL ONLY 10 BURNER OIL NOZZLE 5 OIL PIPING FIGURE 1 8 Integral Compressor Oil Air Metering System IC 790 revised 2010 1 9 D LND Series Manual Introduction INDUSTRIAL COMBUSTION TO ATOMIZING AIR INTEFLOCK SWITCH R E 8 AN fei E e OT a ma N vv o YN LA AN VW WV M ASA RY die dee VW KV added SN A KKK
134. tem in the illustrations as they are described in the following sections 1 2 Description The industrial Combustion D Series oil burners are of the low pressure air atomizing nozzle type Gas burners are of the peripheral mix type All burners feature ignition by spark ignited gas pilot flame With either fuel the burner operates with full modulation A switch permits changeover from automatic fully modulated firing to man ually set firing at any desired rate between minimum and maximum Additional safeguards assure that the burner always returns to minimum firing position for ignition D Series burners are designed for automatic unattended operation except for periodic inspection and mainte nance After selecting the proper overload settings for the starter the rest of the control panel components require little attention except for occasional cleaning IC 790 revised 2010 1 1 D LND Series Manual Introduction INDUSTRIAL COMBUSTION 1 3 Operating Controls The control panel contains a flame safeguard programming control motor starters relays time delays and ter minal strips mounted internally on a panel subbase Lights switches potentiometers a control circuit breaker and flame safeguard displays are mounted externally on the panel as indicated Component Details On Off Burner Switch For gas or oil only Fuel Selector Switch Gas Off Oil For combination gas oil burners only a Gas Position
135. the burner is idle The operation of the oil metering unit is the same as the integral air oil unit 3 Operation Fuel is delivered to the positive displacement metering pump at 10 to 15 psi Metered oil is deliv ered to the common port of a 3 way solenoid valve for transfer to the burner nozzle through the normally closed port or back to the storage tank through the normally open port During pre and post purge metered oil is returned to the tank During normal firing all metered oil is delivered to the nozzle Heavy oil burners have a supplementary nozzle line heater between the metering and the 3 way valve Air enters a rotary vane compressor through an air cleaner where it is compressed to atomizing pressure Air flows from the compres sor to an air oil tank which serves the multiple purpose of dampening air pulsation lube oil mist recovery lube oil and atomizing air storage The compressor rotor is cooled and lubricated continuously by oil under pressure from the air oil tank Oil vapor is extracted by a mist eliminator in the upper section of the tank Atomizing air from the upper tank section is delivered to the nozzle at a constant volume Air pressure increases as the burner firing rate increases Atomizing pressure may be adjusted by the needle valve located on the air oil pump The valve allows air to be bled from the tank to the compressor inlet Delivery rate of the fuel oil metering pump is controlled by the modulating motor through adjus
136. tment Allow the burner to return to low fire position before adjusting high or intermediate settings N High fire combustion analysis typically is 9 to 10 5 CO When conditions covered above are assured refer to Sections 3 9 and 3 10 3 8 2 Oil Bumers 1 Set the fuel selector to OIL On initial startup of a combination burner it is recommended that oil firing be adjusted before gas firing The gas low firing rate is set to match oil low fire rate 2 Be sure the ON OFF switch is in the OFF position and the fuel selector switch is on OIL Actuate the manual reset button of the flame safeguard control to close the safety switch contacts Be sure the MANUAL AUTO switch is in the MANUAL position Set the manual modulating control potentiometer to the LO fire position Open the pilot gas valve if used 3 Set the ON OFF switch to ON The burner will start and pre purge After pre purge the ignition trans former and the gas pilot are energized Before proceeding conduct electrical interference and pilot turndown tests if not previously done Refer to Chapter 4 Sections 4 3 and 4 4 3 6 IC 790 revised 2010 D LND Series Manual 3 9 Normal Operation INDUSTRIAL COMBUSTION 4 Observe the primary atomizing air pressure gauge on the air oil tank The gauge reading should be approxi mately 10 psi during pre purge 5 When the pilot flame is proven the programm
137. u trol motor with linkage connections coordinates the air fuel and NOx control devices to provide proper fuel air N Ox ratios through the firing range The modutrol motor must be able to com plete its full travel range Restrictions will dam age the motor and or the linkage Linkage consists of adjustable levers rods and ball joints that transmit motion from the modutrol motor to the FGR control valve Lever and rod adjustments should be made with the motor in the low fire position The angles of the driven levers on the modutrol motor jackshaft can be adjusted to vary the rate of change The closer the rod is to the lever hub the less distance the rod and control valve blade will travel MODUTROL F G R 2 INC INCREASE LINKAGE ASSEMBLY DEC DECREASE FIGURE 8 3 FGR Control Valve and Air FGR Damper A Warning 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 8 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 t
138. ve will not open unless switch contacts are closed 1 8 6 Air Lube Oil Tank Burner mounted tank stores compressed air for oil atomization and oil for compressor lubrication Contains wire mesh filter to separate lube oil from compressed air 1 8 7 Integral Air Oil Unit Model designation DL DLG DM DMG No 2 through No 5 oil with air atomization Model D42 to 145 These models utilize an integral air compressor oil metering unit which is separately driven at 1725 rpm and mounted on the burner 1 6 IC 790 revised 2010 D LND Series Manual 1 8 Oil System Air Atomizing INDUSTRIAL COMBUSTION Air Inlet Compressed Air Discharge Mechanical Seal Inlet Channel Rotary Vane Air Compressor Fuel Oil Inlet Eccentric Plate Eccentric Shaft and Pin Sleeve Piston Discharge Channel FIGURE 1 5 Integral Air Oil Unit 1 8 9 Air Compressor Air is drawn into the vane type rotary compressor section of the air oil unit through an air cleaner The com pressed air flows to an air lube oil tank which serves the multiple purpose of lube oil mist recovery lube oil sump and air storage The compressor is cooled and lubricated continuously by oil under pressure from the bot tom of the tank Oil vapor is extracted from the compressor air by a mist eliminator in the upper section of the tank Atomizing air flows to the nozzle at a constant volume but air pressure increases as the firing rate increases

IC-SA-790 D-LND Series Manual 10-2010

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