SC Series Forced Draft Burners

Transcription

1 Webster Combustion Technology LLC 619 Industrial Road, Winfield, KS Installation, Startup, Operation and Maintenance Manual SC Series Forced Draft Burners Manual Part No R1 August, 2017 C 2017 All Rights Reserved

2 SAFETY PRECAUTIONS Good safety practices must be used when working on burner equipment. The potential energy in the electrical supply, fuel and related equipment must be handled with extreme care to prevent equipment failures, injuries and potential death. Throughout this manual, the following symbols are used to identify potential problems. WARNING This indicates a potential hazardous situation, which if not avoided, could result in personal injury or death. CAUTION This indicates a potentially hazardous situation which, if not avoided, could result in damage to the equipment. The following general safety precautions apply to all equipment work. WARNING IF YOU SMELL GAS, OPEN THE WINDOWS, ETINGUISH ANY OPEN FLAMES, STAY AWAY FROM ELECTRICAL SWITCHES, EVACUATE THE BUILDING AND IMMEDIATELY CALL THE GAS COMPANY. IN ACCORDANCE WITH OSHA STANDARDS, ALL EQUIPMENT, MACHINES AND PROCESSES SHALL BE LOCKED OUT PRIOR TO SERVICING. IF THIS EQUIPMENT IS NOT INSTALLED, OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS, THIS PRODUCT COULD EPOSE YOU TO SUBSTANCES IN FUEL OR FROM FUEL COMBUSTION WHICH CAN CAUSE DEATH OR SERIOUS ILLNESS AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER, BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM. IMPROPER SERVICING OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND OPERATORS. SERVICING MUST BE DONE BY FULLY TRAINED AND QUALIFIED PERSONNEL. BEFORE DISCONNECTING OR OPENING UP A FUEL LINE AND BEFORE CLEANING OR REPLACING PARTS OF ANY KIND: TURN OFF THE MAIN MANUAL FUEL SHUTOFF VALVES INCLUDING THE PILOT COCK, IF APPLICABLE. IF A MULTIPLE FUEL BURNER, SHUT OFF ALL FUELS. TURN OFF ALL ELECTRICAL DISCONNECTS TO THE BURNER AND ANY OTHER EQUIPMENT OR SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BURNER. Service Organization Information: Company Name Address Date of Startup Lead Technician Phone Number Page 2 Safety Precautions

3 TABLE OF CONTENTS Safety Precautions... A. Introduction... Burner Model Number... SC Specifications... SC Model Configuration... Specification Data... Dimensional Data... B. Component ldentification... C. Installation... D. Special lnstructions For Canadian lnstallations... E. Burner Mounting Criteria... F. Fuel Systems... G. Initial Settings... H. Ignition Systems... I. Start-up & Operating Adjustments... J. Troubleshooting... K. General Maintenance And Care... L. Care of Burner During Shutdown... M. Replacement Parts... N. Warranty Validation & Field Start-up Report... This manual covers the Model SC burners offered by Webster Combustion Technology LLC. These burners can be used in a wide variety of Cast Iron, Firebox, Firetube, Flextube and other applications. They can fire gas, oil and combination gas and oil, with several different operating systems. READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE. A. INTRODUCTION Figure A-1 Nameplate MAIMUM MODEL NUMBER SC12C-15-RM7840L-UL-IRI GAS INPUT RATING SERIAL NUMBER U81375A OIL INPUT RATING MBTU/HR IN.WC GPH PSI WARNING DO NOT ATTEMPT TO START, ADJUST OR MAIN- TAIN THIS BURNER WITHOUT PROPER TRAINING OR EPERIENCE. FAILURE TO USE KNOWLEDGE- ABLE TECHNICIANS CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH. The startup and maintenance of the SC burner requires the skills of an experienced and properly trained burner technician. Inexperienced individuals should not attempt to start or adjust this burner. Every attempt has been made to accurately reflect the burner construction, however, product upgrades and special order requirements may result in differences between the content of this manual and the actual equipment. These special components will be described in the information provided with the burner and should be used as the controlling document. NOTE: This manual must be readily available to all operators and maintained in legible condition. 1. Nameplate Information Each burner has a nameplate with important job details, similar to the nameplates shown in Figure A-1. MINIMUM FUEL NATURAL GAS #2 FUEL OIL VOLTS AMPS HERTZ PHASE HP CONTROL CIRCUIT BURNER MOTOR OIL PUMP MOTOR /2 The serial number represents the unique number for that burner and is a critical number that will be needed for any communications with Webster Combustion. The input rates define the maximum and minimum inputs for that burner, given in MBH for gas and GPH for oil. Air atomized burners show both the oil pressure and air pressure. Pressure atomized burners only list the oil pressure. For gas firing, the gas manifold pressure is given in in wc which is inches of water column. The electrical ratings of the burner are given, with the voltage, current load, frequency and phase (this will either be single or 3-phase). For motors, the motor HP is listed. Page 3 Introduction

4 2. Ratings The ratings for each specific burner are given on the nameplate. The general burner ratings are given in Specification Sheets that follow this section. The maximum inputs are given, based on the type of fuel. Other conditions, like the supply gas pressure or the combination of fuels, emission requirements and control systems may prevent the burner from reaching the lowest firing rate. 3. Product Offering The SC burner can fire natural gas as well as #2 oil. DO NOT USE GASOLINE, CRANKCASE OIL OR ANY OIL CONTAINING GASOLINE. Figure A-2 lists the common variations and options available on this product. The minimum furnace conditions are given in Section C. 4. Your Complete Manual In addition to this manual, there are several other documents that should be considered as part of the complete manual for the burner. All of these documents are needed to support the installation and startup of the unit. These additional items include: a. The wiring diagram, which shows the limits and inter connection of the burner and vessel controls. b. The gas piping schematics, which show the components and their positions in the piping train. c. The unit material list which provides an overview of the burner requirements and a complete bill of material, including the part numbers and description for each item. d. The flame safeguard manual provides the operating sequence for the burner management system. This will be a critical document for troubleshooting any future problems. e. Catalog cuts of the major components. These provide details on the installation, adjustment and maintenance of the components used on the burner. 5. Service, Parts and other Information Service and parts are available from your local Webster Representative. For a list of Webster Representatives, please visit the Webster web site at: or call Page 4 Introduction

5 SC BURNER MODEL CONFIGURATION FIGURE A-2 SC12G -50-LMV51-M.25-M-MP-UL/CSD-1 BURNER SERIES SC G C O SC SERIES HEAD SIZE (INCHES) SC FUELS Gas Gas/Oil Oil BLOWER MOTOR HORSEPOWER / / VGD VGG M Blank M CODES AND LISTINGS UL ULc CSD-1 FM IRI NFPA-85 OIL SYSTEMS Pressure Atomizing MR Modulation By-Pass MP Modulation Simplex Air or Steam Atomization MA Air Atomization MS Steam atomizing GAS TRAIN VENDOR Siemens Siemens Maxon All Others (ASCO) - (std) GAS TRAIN SIZE /2 inches.20 2 inches /2 inches.30 3 inches.40 4 inches GAS SYSTEMS Modulation FLAME SAFEGUARD VENDOR DESIGNATION M Mark AutoFlame - mini mark Nexus Fireye LMV51 Siemens LMV52 Siemens The above represents the common model designations. Contact the factory for other options and special applications. Page 5 Model Configuration

6 Model SC - Specification Data No. 2 Oil No. 2 Oil (1) STANDARD (2,400 STANDARD MBH - EQUIPMENT EQUIPMENT AND 28,800 MBH Input) AND IMPORTANT OPTIONS IMPORTANT STANDARD OPTIONS UL EQUIPMENT STANDARD UL EQUIPMENT AND IMPORTANT OPTIONS (1) AND IMPORTANT OPTIONS Motor, Fan and Air Inlet Control Main Manual Shutoff Motor, Fan and Air Inlet Control Main Manual Shutoff Air Flow Switch (2,400 Main MBH Safety Shutoff - 28,800 MBH Input) Air Flow Switch (also with oil systems using remote (2) Main Safety Shutoff pump) Burner Mounted Control Panel, Second Safety Shutoff Switch and Four Indicator Lights Main Gas Regulator Burner Mounted Control Panel, Switch and Indicator Second Safety Shutoff Flame Lights Safety (2) Control Gas Checking Ultra Flame Violet Safety Scanner Control High and Low Gas Main Pressure Gas Regulator Switches Motor Ultra Starter Violet with Scanner Overloads Metering Gas (modulating Checking systems) Motor Controller (single phase voltage) Dual Fuel Burners Normal Open Vent High and Low (above Fuel Selector Switch Gas Pressure Switches (st d Fuel Selector Switch Only 12,500 MBH) over 2500 MBH) Opt. Linkageless Control Proven Gas Pilot Ignition Oil Drawer Assembly with Diffuser Inverted Housing Proven Gas Pilot Ignition Oil Nozzles Pilot Solenoid Gas Alternate Control Cabinet Positioning Pilot Solenoid Gas Remote Oil Pump Opt. Pilot Gas Regulator & Manual Pilot Gas Regulator & Manual Remote Control Panel Two Safety Shutoff s Pilot Gas Ignition Transformer Pilot Gas Ignition Transformer Low Oil Pressure Switch Inverted Direct Housing Spark Oil Ignition Oil Pressure Gauge Alternate Direct Spark Control Oil Cabinet Ignition Positioning Transformer Oil Metering 1. The Remote configuration Control of Panel each unit will vary with specific job requirements such Air Compressor as input rating, electrical specification and special agency approval codes. The above chart shows those items standard to a basic burner plus a few options that may be added The Indicator configuration lights are of Power each unit On, will vary Call with for Heat, specific Fuel job requirements On and Flame such Fail as input for hard rating, wired electrical panels. specification Alarm, and Low special Water, agency Power, Call for approval Heat, Ignition codes. On, The above and Fuel chart On shows for circuit those items board standard light panels. to a basic burner plus a few options that may be added. 2. Indicator lights are Power On, Call for Heat, Fuel On and Flame Fail.?. Larger motors may be required for single phase or 208 volts Model SC - Specification Data Model SC - Specification Data General General Ignition Ignition Ignition Options Gas Pressure Atomized Air Atomized The above maximum ratings are based on 0 furnace pressure, an altitude of 1000 feet, 90 o F air temperature and 60 HZ electrical supply. Use the following corrections for higher temperatures and altitude. Capacity decreases by 17% for 50 Hertz. Capacity decreases by 4% for each 1000 feet above 1000 foot altitude. Capacity decreases by 5% for each 1 inch of furnace pressure. Capacity decreases by 2% for each 10 o F increase in air temperature over 90 o F. Gas input ratings based on 1000 BTU/cu ft. and 0.64 specific gravity. Sizes and pressure will vary with gas. Essential Ordering Information and Data: Power Supply - Confirm for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired - Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate - Define firing rates in MBH for gas. Fuel to be Burned - Type of gas, including the BTU value. Approval Agency - UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred - Honeywell or Fireye controls. Gas Train Components Preferred - ASCO/ITT, Honeywell or Landis Control System - ON-OFF, Low Fire Start, Low-High-Low, Modulation, Posi-Control Required Options - Mounting plate, limit controls, etc. Gas Gas Fuel Oil Fuel Oil Gas Fuel Optional Oil Fuel Gas Pressure Atomized Air Atomized Power Supply: Confirm for control circuit and electrical supply for burner motor(s) (voltage, frequency and phase). Describe Boiler or Heater to be Fired: Including the manufacturer, model number, furnace pressure and furnace size. Firing Rate: Define firing rates in MBH for gas. Fuel to be Burned: Type of gas and/or oil, including the BTU value. Approval Agency: UL, FM, IRI (GE GAP), CSD-1, NFPA, Mil spec and local codes, if applicable. Flame Safety Control Preferred: Honeywell, Fireye or Siemens controls. Gas Train Components Preferred: ASCO/ ITT, Honeywell or Landis Control System - Modulation, Posi-Control Required Options - Mounting plate, limiting controls, etc. Page 6 Specification Data

7 Model SC - Dimensional Data (Dimensions are +/- 1/4 inch) Fuels Burned and Control Systems - Natural Gas - Light #2 Oil, Mechanical Pressure - Modulating or Micro Modulation - Control Circuit Requires 120 vac, 60 Hz, Single Phase Voltage Supply Model SC burners can be packaged to meet specific requirements of IRI, FM, GE GAP, NFPA, MIL spec. or other special insurance or local code requirements. Page 7 Dimensional Data

8 B. COMPONENT IDENTIFICATION This secion shows the different common components used in the SC burner line and should be helpful to identify parts described elsewhere in this manual. Gas Separator Solenoid Oil Pressure Switch Oil Pressure Gauge Oil Lines Secondary Fuel Mod Motor Secondary Fuel Supply Figure B-1 SC Dual Fuel Burners Primary Fuel Butterfly Primary Fuel Supply Pilot Gas Regulator Louver Box Air Pressure Switch Control Cabinet Figure B-2 SC Burner Side View Oil Pressure Gauge Control Transformer Combustion Head IgnitionTransformer Blower Motor Page 8 Identification

9 UV Sight Port Secondary Gas Orifices Oil Nozzles Primary Gas Orifices Spark Plug Diffuser Assembly Figure B-3 SC Head Figure B-4 Control Panel Hard Wired Design Control Relays Burner Motor Starter Switch / Light Panel BMS Display Burner Management System Terminal Strip Pressure Gauge Air Chamber Belt Guard Air Filter Electric Motor Compressor Figure B-5 Air Compressor Air Discharge Connection Page 9 Identification

10 SECONDARY ORIFICE PLATE MOUNTING FLANGE SECONDARY GAS CONNECTION PRIMARY ORIFICE PLATE SECONDARY ORIFICE TUBES OUTER CYLINDER PRIMARY GAS CONNECTION HOUSING MTG. FLANGE GAS TUBE SECONDARY AIR SLOTS IGNITION HOLDER INNER CYLINDER PRIMARY GAS MANIFOLD DIMENSION WILL VARY DEPENDING ON VESSEL INSERTION DEPTH SECONDARY GAS MANIFOLD Gas Orifice Part Number and Description CHECK VALVE OIL NOZZLE ACCESS COVER OIL SUPPLY LINE Figure B-8 Drawer Assembly Page 10 Identification

11 C. INSTALLATION Prior to installing the burner, the site conditions and utilities need to be evalulated. This section provides some general questions that can help the review process. Inspect the burner for any undetected damage that may have occurred during shipment or by job-site handling. Special attention should be given to the control panel and protruding parts. Check wiring connections and fasteners for tightness. Verify that all ship loose (or separately shipped) items are on hand. This normally will be gas train components, mounting lugs and insulating rope. Also, front mounting plate and remote oil pump set, if supplied. The burner material list included with the instruction manual serves as a good checklist for this purpose. 1. Is there adequate outside ventilation to supply the needed air for safe combustion as required by your local regulatory agency? 2. If a burner mounting plate is required, is it available and does it meet specifications? (See Section E) 3. Is the correct voltage available for the control circuit and is the correct voltage available for the blower motor as well for the remote oil pump set and air compressor, if used? 4. Will the burner properly fit the boiler or heater with ample clearance on top, bottom and sides? 5. If a gas burner, will there be adequate gas pressure to assure the specified firing rate? 6. If a combination burner, is gas available at the burner location? 7. If a combination burner, what is the age and condition of the oil tank(s) and will there be special piping arrangements needed to deliver the oil to the burner? Important Note: The SC series burners must be operated with a two-pipe system. 8. If a retrofit installation, has the same oil grade always been used? Does it meet the grade specified on the burner s rating plate? 9. Is there adequate flue provisions to assure SAFE and proper venting of the burner? 10. All manuals should be reviewed and understood and stored in a convenient place. 11. Teflon tape should not be used on any field piping. 12. Rope gaskets should be used between vessel and mounting plate, and between mounting plate and burner. 13. Gas piping should be flushed (cleaned) prior to use. 14. Check minimum straight lengths for gas pressure regulator and/or sensing line. 15. Oil piping to be flushed (cleaned) prior to use. 16. Check pump suction pressure (max 10 Hg) or max press (3 psig) if transfer pump is used or tank elevation is higher than the pump. 17. Strainer before oil pump, sized for max pump suction capacity. 18. If multiple vessels connect to a single stack, are they sized and designed to maintain +/- 0.1 wc draft at the vessel outlet under all operating conditions. 19. Is stack designed to maintain +/- 0.1 wc at outlet during all operating conditions. WARNING DO NOT USE TEFLON TAPE OR COMPOUNDS CONTAINING TEFLON. THIS COULD DAMAGE THE VALVES CREATING AN UNSAFE OPERATION 20. Is the burner mounting plate and burner head sealed with rope gasket? (See Figure E-2) 21. Is there a drip leg in the gas supply to capture foreign material? (See Figure C-1) 22. Is the piping between the gas train and burner done in a manner that will minimize the pressure drop? 23. Has all of the piping been pressure checked for leaks? 24. Is the combustion chamber of proper size and is the center-line height of the burner head adequate? (See charts C-2 & C-3.) CAUTION THE COMBINATION BURNER SHALL ONLY BURN THAT GRADE OF OIL SHOWN ON THE RATING PLATE. DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE OR TOIC CONTAMINANTS. Page 11 Installation

12 Figure C-1 Typical Gas Piping PILOT LINE (FIELD PIPED) PILOT GAS PRESSURE REGULATOR PILOT SHUTOFF VALVE GAS SUPPLY LOW PRESSURE SWITCH MANUAL GAS SHUTOFF VALVE PILOT SOLENOID VALVE HIGH PRESSURE SWITCH DRIP LEG GAS PRESSURE REGULATOR IF APPLICABLE, WEBSTER-SUPPLIED GAS TRAIN SHUTOFF VALVE SHUTOFF VALVE LEAK TEST VALVE BURNER Chart C-2 Chart C-3 TYPICAL COMBUSTION CHAMBER SIZE FOR FIREBO BOILERS, WATERTUBE & CAST IRON SECTIONAL TYPES TYPICAL COMBUSTION CHAMBER SIZE FOR SCOTCH MARINE FIRETUBE BOILERS D. SPECIAL INSTRUCTIONS FOR CANADIAN INSTALLATIONS 1. The installation of a burner shall be in accordance with the regulations of the provincial installation requirements, or in their absence, the following shall govern: Gas Burners--CGAB149.1 and CGAB149.2 Authorities having jurisdiction should be consulted before installations are made. 2. All electrical wiring shall be done in accordance with the Canadian Electrical Code, Part I. 3. The installer shall identify (label) the main electrical power disconnect and the manual shut-off valve on the gas and/or oil supply drop-line to the burner. 4. 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, no more than iwc. Page 12 Installation/Canadian Installations

13 E. BURNER MOUNTING CRITERIA It is of vital importance that the burner be properly mounted to the boiler or appliance being fired. Improper mounting can cause leakage of the hot gases back around the burner head resulting in warpage and deterioration. The following illustrations show the proper way the burner must be installed to validate warranty conditions. TYPICAL SC BURNER REFRACTORY FRONTPLATE Figure E-1 Refractory Dimension A B Dimensions - Inches MODEL DIM. A DIM. B SC SC SC SC SC SC SC SC SC SC SC SC SC Contact Webster for more detailed refractory drawings. BURNER MUST BE LEVEL REFRACTORY FRONT PLATE THIS SURFACE MUST BE SEALED AGAINST THE VESSEL. CHECK VESSEL MOUNTING REQUIREMENTS. THIS SURFACE MUST BE SEALED AGAINST THE VESSEL. CHECK VESSEL MOUNTING REQUIREMENTS. FILL VOIDS BETWEEN FRONT PLATE AND VESSEL WITH CERAMIC BLANKET 4 DEEP OR AS DEFINED BY VESSEL MANUFACTURER IF GAP IS OVER 3/16 WRAP BURNER NOSE WITH HIGH TEMPERATURE CERAMIC INSULATION ROPE ATTACHMENT TO VESSEL VARIES WITH MANUFACTURE. (FOLLOW VESSEL MANUFACTURER S RECOMMENDATION) THE GAS PIPING FROM THE BURNER TO THE TRAIN SHOULD HAVE AS FEW ELBOWS AS POSSIBLE TO REDUCE PRESSURE DROP. Figure E-2 Burner Mounting Instruction Page 13 Burner Mounting Criteria

14 F. FUEL SYSTEMS The SC burner can be equipped with a wide range of fuel and operating systems to control the fuel, air, modulation and pilots. This section describes how these systems operate. Burner start-up is expected to be done by service personnel who are qualified in the basics of mechanical know-how. The following illustrations and information is supplied to identify the various fuel; air and ignition devices that have Adjustment Features. All adjustments can be done with common place tools normally carried by burner and boiler service personnel. NOTE Refer to the bulletins included in the manufacturer s data section of the burner instructions manual for items below. 1. Pressure atomized oil systems MP - Modulating Simplex Nozzle Oil Metering 2 Low Oil Pressure Switch Main Oil Solenoid Safety Oil Solenoid 1 1 Gauge Port Adjustment Oil Nozzle Return to Tank, (No Manual s in this Line) Suction Supply Line Field Piped Check By Others Shutoff Check 1 Strainer By Others (Unless Specified on Order) Oil Pump 1 2 Notes & Options These Lines are Field Piped if a Remote Pump is Used Usage Requirement Varies with Code MR - Modulating Return Flow Nozzles Back Pressure Reg. 2 Low Oil Pressure Press. Sw. Gauge 1 Main Oil Solenoid Safety Oil Solenoid Suction Supply Line Shutoff 1 Check Strainer Gauge Port Oil Pump Inline Check Oil Nozzle (Bypassing) Notes & Options By Others (Unless Specified in Order) Return to Tank (No Manual s in this Line Check 1 Check Oil Metering Pressure Gauge 1 2 These Lines are Field Piped if a Remote Pump is Used Required Above 20 GPH if a Remote Pump is Used Field Piped Page 14 Fuel Systems

15 2. Air Atomized Oil Systems Air Filter Ball (man. set to adjust air volume & high fire air pressure) Compressor Safety Air Chamber Air pipe same size as discharge opening in air chamber (field Piped) Low Atomizing Pressure MA - Modulating #2 Oil Check Gauge Nozzle Pressure Gauge Oil Metering N.C. Main Oil Safety Oil Ball Oil Gauge Flexible Metal Hoses or Copper Tubing Low Oil Pressure Gauge Ball or Gate Gauge Relief Compound Gauge Strainer Check Check Gate Field Piped Return to Tank Oil Suction Field Piped MA or MS - Modulating House Air or Steam 125 PSIG Max. Atomizing Steam Condensate Return Steam Trap Ball or Gate Steam Syphon Steam Strainer Drip Leg 300 lb. Gauge Pressure Reducing Ball or Gate Field Piped Metering Lever Ball Linked to Mod. Motor N.C Atomizing Steam Syphon Low Atomizing Pressure Switch Check Steam Syphon Gauge NOTE: House air does not use steam Syphon or Steam Trap Page 15 Fuel Systems

16 2. Gas Systems Illustrated Gas Trains by Capacity and Code: The following illustrations show the Webster configuration for UL, FM and IRI as grouped by UL capacity ratings. Refer to the legend below for component part identification. These illustrations are not to be used for field erection and/or system design purposes. UL Capacity Range BTU/Hr. Operation Mode Webster Designation Code UL FM Illustration To 2,500,000 2,500,001 to 5,000,000 5,000,001 to 12,500,000 12,500,001 and Up Modulating Modulating Modulating Modulating Modulating Modulating Modulating M M M M M M M UL-FM Modulation Gas Piping Diagram - Up To 2,500 MBH Firing Rate UL Modulation Gas Piping Diagram - 2,500 To 5,000 MBH Firing Rate Page 16 Fuel Systems

17 FM Modulation Gas Piping Diagram - 2,500 To 5,000 MBH Firing Rate UL Modulation Gas Piping Diagram - 5,000 To 12,500 MBH Firing Rate FM Modulation Gas Piping Diagram - 5,000 To 12,500 MBH Firing Rate UL Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate Page 17 Fuel Systems

18 FM Modulation Gas Piping Diagram - Over 12,500 MBH Firing Rate G. INITIAL SETTINGS The burner will be set at the factory for normal initial settings. These are only rough settings that must be adjusted at startup to match the furnace, fuel pressure and environment of the specific application. These general settings are covered in this chapter as a means of checking the burner or readjusting the burner if the settings are lost. Presets can change during shipping. COMBUSTION AIR CONTROL Panel Adjusting Screw Air Proving Switch 1. OIL NOZZLE POSITION The oil nozzle will be adjusted at start-up and may be moved in or out from this initial setting. 2. AIR PROVING SWITCH The air proving switch has been adjusted at the factory for an initial setting. If the switch trips during initial start-up, turn the adjustment screw CCW two full turns to reduce the trip pressure setting. Air Flow Interlocking Switch CAUTION ACTUATOR MOUNTINGS CAN BE BENT OR MOVED DURING SHIPMENT AND INSTALLATION. THEY MUST BE CHECKED PRIOR TO OPERATION AND ANY FAULTS CORRECTED. FAILURE TO CORRECT A MISALIGNED CONTROL WILL RESULT IN PREMATURE FAILURE. Page 18 Initial Settings

19 H. IGNITION SYSTEM Every burner set-up is different, therefore the positions below are indications only and tuning must be done by fully trained and qualified personnel. 1. Pilot A crucial part of reliable burner operation is a dependable pilot. The way the SC burner operates is that the primary zone is lit first, thus acting as a pilot, before the secondary fuel valve is opened and the burner can operate the entire operating range. The spark plug position can be seen in figure H-1. Pilot gas pressure should be measured at the 1/8 port located downstream of the primary solenoid valve. 2. Air Damper Position The air damper should be near close at low fire and close to full open at high fire. 3. Gas Modulating Control Position The gas valve should be open about 10% at low fire and stroked at least 60% open at high fire. 4. Oil Modulating Control Position For pressure atomizing, the low fire position should be adjusted to get the correct low fire pressure, as stated on the rating label. Typically, this would be 100 psi for simplex systems and 65 psi for return flow nozzles. The high fire position should be about 45º to 60º travel from low fire. For air atomizing, the low fire should be on about #2 position and the high fire should be about the #8 position. Spark Plug Figure H-1 I. STARTUP AND OPERATING ADJUSTMENTS 1. Pre-Start Check List 2. Burner Drawer Adjustments 3. Gas Setup 4. Pressure Atomized Oil Setup 5. Air Atomized, #2 Oil Setup 6. Operating Control Adjustments 7. Limit Tests 8. Pilot Test 9. Burner Shutdown 10. Restarting After Extended Shutdown This section covers the startup and operating adjustments of the Webster Models. WARNING BURNER STARTUP, COMBUSTION ADJUSTMENTS AND LIMIT CONTROL ADJUSTMENTS SHOULD BE PERFORMED ONLY BY TRAINED, EPERIENCED SERVICE TECHNICIANS. ATTEMPTING TO PER- FORM THESE FUNCTIONS WITHOUT THE PROPER TRAINING CAN RESULT IN EQUIPMENT DAMAGE, PERSONAL INJURY OR DEATH. Before proceeding with startup and adjustment, be sure that overall installation is complete. Review the boiler operating and installation manual, as well as all control manuals to verify that equipment is ready for operation. These manuals must be read prior to start of equipment. If you are not qualified to service this equipment, DO NOT TAMPER WITH THE UNIT OR CONTROLS - CALL YOUR SERVICEMAN. A block diagram of the startup sequence for the SC burner can be found on page 25, Figure I-3. When finished with startup, document valve and linkage positions, pressures, and settings for future reference. READ AND SAVE THESE INSTRUCTIONS. During purge, all solenoids, including the gas separator solenoid valve, are closed and are to remain closed until called upon. After purging the system for at least 30 seconds, the spark plug is activated. Waiting for one second for the spark to initiate, the pilot solenoid valve is opened which will ignite the primary zone. When the flame safeguard system detects a strong signal, it will open the main fuel valve to start the ignition of the secondary zone. Following a 4-second delay, the gas separator solenoid valve will open and the pilot solenoid can be closed. From this point on, the burner can be driven to low fire. Page 19 Ignition Systems/ Startup and Operating Adjustments

20 1. Pre-Start Check List Before starting the burner, a complete review of the installation, wiring and piping of the burner, boiler and all supporting equipment must be complete and all of these items must be ready for operation prior to starting. The following is a general review: All wiring is connected. Gently pull on all the wires to make sure that they are connected properly. All fuel lines are connected and tight. Pilot gas is connected. Burner is mounted to vessel and floor, with all bolts secured. The stack is connected and routed to the outside. Draft controls are installed and operational, if needed. Gas vent lines are connected and routed to the outside, if required per code. Do not start the unit unless all cleanout doors are in place and secured. The vessel is completely installed, filled with water and operating controls checked. Support equipment is in place and ready (feed pumps, draft controls, steam/hot water systems, boiler limits and controls and feedwater systems). A load must be available for the burner startup and adjustment process. The burner must be operated at high rates for extended periods and the load must be able to use this energy. A combustion analyzer with O 2 and CO (for gas) must be available to tune combustion. A smoke spot tester must be available for oil firing. A NOx analyzer must be available. All of these analyzers must be recently calibrated and able to provide accurate readings. Other test equipment, including manometers, gauges and volt meter shall be available. Manometer or gauge on the gas manifold. Manometer or gauge before and after gas pressure regulator. Draft gauge or manometer (at stack outlet). Draft gauge or manometer for furnace pressure. 2. Burner Drawer Adjustments The burner drawer has several adjustments built into the design that allow the combustion to be tuned. While this can simplify the combustion tuning process, care must be used to retain the relative position of other components during this sequence. If these adjustments are required, follow the sequence listed to perform the adjustments. The burner drawer must be removed for access to components, follow the following steps: a. Loosen and remove the screws on the burner drawer. b. Disconnect the scanner by screwing it off of the scanner tube. In some cases, the scanner simply pulls out, with a spring tension. Secure the scanner so that it is protected from shock. c. Pull the drawer out, holding it centered in the opening to prevent it from hanging up while being pulled. d. Set the drawer down horizontally. To re-install the burner drawer, simply work the procedure in reverse. 3. Gas Setup a. Place the burner switch in the OFF position b. Place the burner management system in manual mode. If this is a combination fuel burner, make sure the fuel selector switch is on GAS. c. Place the burner management system in the low fire position. d. Close the downstream manual shutoff valve (closest to the burner head) on the gas train. e. Turn the electrical power on for the burner, boiler and related components. f. Verify that the gas metering valve is nearly closed, the vent valve (if equipped) is operating and the gas pilot valve is not open (the solenoid will hum and feel warm). g. Turn the burner switch on. This will start the blower motor and initiate the prepurge cycle. h. When the prepurge sequence is complete and the low fire start switch is made, the flame safeguard should indicate the presence of a flame. i. When the pilot flame is established, the flame safeguard will energize the main gas valve (indicated with the Fuel Light). This operation of the main fuel valves must be visually checked by observing the valve stem operation. j. After the timer has completed the trial for main flame, the burner will go out on alarm (the closed manual gas valve prevented the burner from lighting). At this time, the gas valves must be visually checked to verify that they have closed. This test sequence proves the proper operation of the primary control. k. Press the reset button and restart the burner. When the pilot has started, open the manual gas valve to allow the main flame to start. l. After a few seconds, the combustion analyzer should have an accurate reading of the O 2 in the stack. Fig. I-1 shows the typical range of O 2 at different firing rates, and the burner should be adjusted to be within this range. Rough settings for low and mid fire combustion settings are adequate at this time. Once the high fire is set, the other settings can be fine tuned. Page 20 Startup and Operating Adjustments

21 m. Operate the burner until the boiler is warmed up and near the operating pressure or temperature. Increase the firing rate. Put the low fire hold switch in auto mode, while monitoring and adjusting the O 2 level. Adjust the gas pressure regulator as needed to reach the high fire input. n. Adjust the high fire input to match the maximum input listed on the rating label. At high fire, the gas butterfly valve should be at least 75 degrees open (more if available gas pressure is low), and the gas pressure regulator adjusted to obtain the rating. The input should be measured using the following: Calculating Natural Gas Input Gas MBH = HHV x [(Patm + Pgas)/29.92] x [520/(Tgas +460)] x [measured ft3/sec] x [3600 sec/hr] Where: MBH = 1000 s of BTU/H input HHV = Higher heating value of gas, BTU/cubic feet Patm = Atmospheric pressure in inches Hg Pgas = Gas pressure before gas meter in inches Hg (inches HG = PSIG x 2.04) Tgas = Gas temperature at the flow meter, in degrees F Measured ft 3 = volume of gas measured by meter sec = Time for measured ft 3 to flow through meter Note: Some gas meters require a 6 inch wc correction to Pgas. Consult your meter calibration data. NOTE: The listed manifold pressures are an approximate value and can vary with operating conditions and normal tolerances. The fuel flow rate must be measured to obtain an accurate input value. o. Adjust the air damper to obtain the correct NOx and CO levels. p. Modulate the burner to low fire, adjusting the O 2 level as the burner modulates to match the desired emission level. q. Adjust the low fire input and air damper adjustments. If the NOx is too high, close the primary butterfly valve more. If the CO is too high, close the air damper in small increments. r. Re-adjust the midfire points for the correct emission level. s. Adjust the low gas pressure switch to be 10% below the lowest expected gas pressure. With a gauge or manometer at the same location as the low gas pressure switch, modulate the burner to determine the firing rate with lowest gas pressure. At the lowest gas pressure, adjust the low gas pressure setting up until the switch breaks and causes the burner to shutdown. From the scale reading of the switch, adjust the setting to a pressure that is 10% lower than the shutdown pressure. For example, if the switch opened at 10 inches as indicated on the low gas pressure switch, the switch should be adjusted to a reading of 9 inches. Remove gauge or manometer and plug opening. Cycle the burner on and off to determine if the limit works properly. If the limit causes nuisance shutdowns because of small pressure drops during startup, reduce the pressure setting an additional 5%. t. Adjust the high gas pressure switch to be 10% above the highest expected gas pressure. With a gauge or manometer at the same location as the high gas pressure switch, modulate the burner to determine the firing rate with the highest gas pressure. At the highest gas pressure, adjust the high gas pressure setting down until the switch opens and causes the burner to shutdown. From the scale reading of the switch, adjust the setting to a pressure that is 10% higher than the shutdown pressure. For example, if the switch opened at 10 inches as indicated on the high gas pressure switch, the switch should be adjusted to a reading of 11 inches. Remove the gauge or manometer and plug the opening. Cycle the burner on and off to determine if the limit works properly. If the limit causes nuisance shutdowns because of small pressure changes during startup, increase the pressure setting an additional 5%. u. The burner should be operating at low fire to adjust the air proving switch. Turn the adjusting screw cw (in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 1/2 turns from the point of shutdown. Check the operation at higher rates. 4. Pressure Atomized Oil Setup The pressure atomized oil system has a limited range of adjustment for low and high fire, dictated by the operation of the oil nozzle. The combustion air must be adjusted to match these rates. a. Place the burner switch in the OFF position. b. Place the burner management system in manual mode. If this is a combination fuel burner, make sure the fuel selector switch is on OIL. c. Place the burner management system in the low fire position. d. Turn the electrical power for the burner, boiler and related components on. e. Verify that the oil metering valve is nearly opened (the valve will be closed at high fire). f. Turn the burner switch on. This will start the blower motor and initiate the purge cycle. Page 21 Startup and Operating Adjustments

22 g. When the prepurge sequence is complete and the low fire start switch (if used) is made, the pilot valve will open and the pilot flame should be visible through the burner sight port. h. When the pilot flame is established, the flame safeguard will energize the main valves (indicated with the Fuel Light), and the burner should ignite at low fire. This operation of the fuel valves must be visually checked by observing the valve stem moving up with a motorized valve or hearing the clicking noise from a solenoid valve. NOTE: If the burner is not operating as indicated, follow the troubleshooting steps to determine the problem and corrective action. i. The main flame may not light on the first attempt, because it must fill the oil lines before providing oil to the nozzle. Press the reset button on the flame safeguard to restart the burner. j. In a few seconds, the combustion analyzer should have an accurate reading of the O 2 in the stack. The O 2 level should be between 4% and 7%, and the nozzle oil pressure should be between 50 and 70 PSIG return line pressure. Do not attempt to fine tune combustion until the high fire has been set. WARNING DO NOT ATTEMPT TO START THE BURNER WHEN ECESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS HOT. k. Operate the burner until the boiler is warmed up and near the operating pressure or temperature. l. Increase the firing rate, using the potentiometer or put the low fire hold switch in auto position, while monitoring and adjusting the O 2 level. m. At high fire (end of the modulating motor travel), adjust the high fire input (open or close the fuel valve) to match the maximum input and/or pressure listed on the rating label. The fuel metering valve should be nearly closed (or closed) at this point and the nozzle pressure should be at the pressure rating indicated on the rating label (return line) for the SC. n. Modulate the burner to low fire, adjusting the O 2 level as the burner modulates. p. Adjust the low fire input and air damper adjustments. q. Re-adjust midfire points for correct emission levels. r. Adjust the NOx levels at low and midfire rates to be about 10% under the guaranteed levels or as required for the gas firing. s. The burner should be operating at low fire to adjust the air proving switch. Turn the adjusting screw cw (in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 ½ turns from the point of shutdown. Check the operation at higher rates. t. Adjust the oil pressure switch to trip and shutdown the burner at a pressure that is 10% lower than the supply oil pressure. 5. Air Atomized, #2 Oil Setup The air atomized oil system has the potential for a large turndown range similar to gas and has the potential to be adjusted to different low fire rates. See the burner nameplate for details on actual rates for this burner. a. Place the burner switch in the OFF position. b. Place the burner management system in manual mode. c. Place the burner management system in the low fire position. d. Turn the electrical power for the burner, boiler and related components on. e. Verify that the oil metering valve is at the nearly closed position. f. Turn the burner switch on. This will start the blower motor and initiate the purge cycle. g. When the prepurge sequence is complete and the low fire start switch is made, the pilot valve will open and the flame should be visible through the sight port. h. When the pilot flame is established, the flame safeguard will energize the main oil valves (indicated with the Fuel Light), and the burner should ignite at low fire. This operation of the main fuel valves must be visually checked by observing the valve stem moving up with a motorized valve or hearing the clicking noise from a solenoid valve. NOTE: If the burner is not operating as indicated, follow the troubleshooting steps to determine the problem and corrective action. WARNING DO NOT ATTEMPT TO START THE BURNER WHEN ECESS OIL HAS ACCUMULATED, WHEN THE UNIT IS FULL OF VAPOR, OR WHEN THE COMBUSTION CHAMBER IS HOT. i. After a few seconds, the combustion analyzer should have an accurate reading of the O 2 in the stack. The O 2 level should be between 4% and 7% (see Figure I-1 for O 2 rates), and the nozzle oil pressure should be between 5 and 15 PSIG. Do not attempt to fine tune combustion until the high fire input has been set. The air damper should be positioned for the correct low fire settings. The atomizing air pressure can be adjusted using the air bleed valve. j. Operate the burner until the boiler is warmed up and near the operating pressure or temperature. k.increase the firing rate, using the manual potentiometer, while monitoring and adjusting the O 2 level. Adjust the oil pressure and atomizing air pressure as needed to reach high fire position. Page 22 Startup and Operating Adjustments

23 Natural Gas < 9 ppm NOx < 30 ppm NOx #2 Oil Figure I-1 Typical O 2 levels % Power Rate Min O 2 Max O 2 Min O 2 Max %O 2 Min O 2 Max %O 2 30% % % % l. At high fire (end of the modulating motor travel), adjust the high fire input to match the maximum input listed on the rating label. Using a flow meter, the fuel input may be measured using the following equation, Oil GPH = [Gal end Gal start] x [3600 sec/hr] / [measured sec] Where Gal end = meter gallons at end of test Gal start = gallons at start of the test Measured sec = measured time of test GPH = Gallons of oil per hour FIGURE I-2 Typical Atomizing Air Pressure % Rate Minimum m. Adjust the NOx level to be about 10% below any guaranteed NOx performance. n. Modulate the burner to low fire, adjusting the O 2 level as the burner modulates. o. Adjust the low fire input, using the fuel and air damper adjustments. p. Re-adjust the midfire points for the correct O 2 levels. See Figure I-2 for Atomizing Air Pressure. q. The burner should be operating at low fire to adjust the air proving switch. Turn the adjusting screw cw (in) until the burner trips out (shutdown caused by the air flow switch). Turn the adjustment screw ccw (out) 1 ½ turns from the point of shutdown. Check the operation at higher rates. 6. Operating Control Adjustments The operating controls must be adjusted to properly cycle the burner ON and OFF and provide modulation. The controls should not force the burner into rapid ON-OFF cycles, as this will cause premature failure of the motor and operating equipment. The operating control must be adjusted to provide the ON pressure or temperature desired. It must allow the burner to come on and start before the temperature or pressure drops into the modulating range. The OFF pressure or temperature must be sufficiently above the ON point to allow a reasonable run time. The modulating control must be adjusted to start modulation at some reasonable point below the ON temperature or pressure and provide modulation to high fire at the lowest temperature or pressure. 7. Limit Tests Once the burner has been started and the operating pressures and temperatures have been set, the limit switches need to be adjusted so that they will trip if the pressure or temperature exceeds the operating value, but will not trip with normal variations. The switch should be checked for proper operation by allowing the temperature or pressure to vary below (or above) the recommended level to insure that they provide safe shutdown before the burner operation is affected. In some high pressure or temperature switches, where the temperature or pressure cannot be set high enough to trip the switch, the switch can be checked by lowering the set point to prove that the switch will provide safe shutdown. The limit switches include the air proving interlock switch on the burner. Limits for gas operation could include the high and low gas pressure switches and for oil firing, the high and low oil pressure switches, high and low oil temperature switches and the atomizing air pressure switch. If in doubt about which limits are on a burner, refer to the wiring diagram that will show each item. Limit switches need to be checked regularly to ensure they are operating properly. See the maintenance section. Page 23 Startup and Operating Adjustments

24 8. Pilot Test Once the burner has been set for the firing rates intended, the pilot must be checked for proper operation and safety. The minimum pilot test is done to insure that a pilot which can be seen by the scanner will light the main flame. a. During a startup sequence, measure the time required to light the main flame after the fuel valves have been energized. This will be used to monitor the test with reduced pilot. b. Lock the flame safeguard into the pilot position (refer to the manual for the flame safeguard for this setting) c. Adjust the gas pressure regulator to the pilot for a minimum value while still holding the minimum signal strength for the scanner. d. Release the flame safeguard from the pilot position and allow it to cycle though the main flame proving sequence. e. This reduced pilot must reliably light the main flame. Monitor the time from the main fuel valve opening and do not allow the burner to continue if the time is more than an additional two to three seconds from the initial time measured above. f. Run through two or three cycles. g. Failures due to reduced scanner signal are also acceptable. WARNING THE MINIMUM PILOT TEST REQUIRES CLOSE SUPERVISION OF THE COMBUSTION PROCESS. FAILURE TO CLOSELY MONITOR THE MAIN FLAME TEST TIME COULD RESULT IN DAMAGE, INJURY OR DEATH. h. If the pilot does not light the main flame under these test conditions, adjust the fuel pressure to the primary (pilot) zone i. The infrared detector must be tested for hot refractory pickup. This test is performed to make sure that the scanner does not see hot refractory that could be mistaken for a flame. j. After the burner has been operating for some time at high input levels and the refractory in the vessel is hot, the burner should be cycled off while monitoring the scanner signal. k. The flame signal should drop off quickly as the flame goes out and should be well below the minimum level (indicating a flame) at the end of the post purge cycle. l. The UV detector must be tested for spark pick-up. Turn the burner on, with the pilot shut off, during the ignition cycle the flame signal should be well below the minimum level (indicating a flame). m. If the flame signal does not drop out as required, this may indicate a faulty scanner or amplifier. 9. Burner Shutdown Normal operation of the burner will allow the operating controls to shut the burner down when the load demand is satisfied. If the burner needs to be shut down for any reason, the ON-OFF switch can be used to quickly turn the burner off. This will instantly cause the fuel valves to close and start a post purge cycle to remove any unburned fuel from the vessel. In an emergency shutdown, all fuel and electrical power should be de-energized or turned off to secure the burner. This would include the main power disconnect, the manual gas shutoff valve at the drop down line and if equipped, the manual oil valve to the nozzle. It is recommended that the burner be manually driven to low fire before turning the burner off, as this reduces the dynamic and thermal stress. If the burner will remain off for some time, the manual fuel valves, fuel pumps and power supply should be turned off. CAUTION ALWAYS KEEP THE FUEL SUPPLY VALVE SHUT OFF WHEN THE BURNER IS SHUT DOWN FOR AN ETENDED PERIOD OF TIME. 10. Restarting After Extended Shutdown Extended shutdowns require the same startup process as those outlined above. In addition, the following advanced cleaning must be done: a. The air atomized oil nozzle should be removed and cleaned, if pressure atomized they should be replaced. Use care in cleaning to preserve the sharp edges of the nozzle, which are required to maintain good atomization. b. The oil filter and strainer must be removed and cleaned prior to starting. CAUTION DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS ARE SECURED IN PLACE. Page 24 Startup and Operating Adjustments