GP COMBUSTION EQUIPMENT INC 100 Sheldon Dr., Units 16/17 Cambridge, Ontario N1R 7S7. Model C Forced Draft Burners. Natural Gas or Propane MODEL C10

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1 Model C Forced Draft Burners Natural Gas or Propane MODEL C10 MODEL C4 GP COMBUSTION EQUIPMENT INC 100 Sheldon Dr., Units 16/17 Cambridge, Ontario N1R 7S7 Telephone: (519) Telefax: (519)

2 TYPE C FORCED DRAFT BURNERS USING NATURAL GAS AND PROPANE High Fire Input Range Low Fire Burner Model Maximum MBH Minimum MBH Minimum MBH Power Supply Standard C4 - * /1/60 C4.1 - * /1/60 C4.5 - * /1/60 C6.2 - * /1/60 C8 - * /1/60 C8.1 - * /3/60 C * /3/60 C * /3/60 C10 - * /3/60 C * /3/60 C * /3/60 C * /3/60 *Insert type of fuel; N - Natural Gas; P - Propane Gas Capacity ratings are based upon an approximation of 80% combustion efficiency using higher heating value of the fuel and maximum burner capacity at an elevation of 1000 feet above sea level. Capacity will be reduced 4% for each additional 1000 feet of elevation. Maximum input capacity is based on zero furnace pressure. Capacity decreases with pressurized furnace, 3% for each 0.25" wc increase in furnace combustion chamber pressure. Gas input based on 1000 Btu/Cu.Ft. and 0.60 specific gravity. Ignition - C6 to C12 - pilot ignition C4 - direct spark or pilot ignition Modulating, high-low, or on off control systems with low fire start or proven low fire start with prepurge or pre-postpurge air control are available. Control panel with on-off switch, fuse and two pilot lights is standard on sizes C8.1 to C12.9 and all three-phase burners. Optional panel is available for sizes C6.2 to C8. Modulating burner panels have two additional pilot lights, manual-auto switch and potentiometer.

3 NOTICE This Burner instruction manual should be kept with other literature on your boiler room equipment as a complete reference source for maintenance and service. It contains information intended to support the following functions: 1. General Installation 2. Start-up 3. Service Specific installation requirements and instructions should always be covered in appropriate engineering drawings and/or specifications that detail the applicable building codes, etc. Information contained herein is to be used as a guide ONLY and not as the final authority. WARNINGS Improper servicing of this equipment may create a potential hazard to equipment and operators. SERVICING MUST BE DONE ONLY 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 manual fuel shutoff valves including pilot gas cock, if applicable. If a multiple fuel burner, shut OFF all fuels. Turn OFF all electrical disconnects to the burner and any other equipment. FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. Don t touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. Included herein are various pieces of manufacturer s literature covering the more complex pieces of equipment. Manufacturer s literature is not included on commonplace hardware or on components, which are not field repairable. These items should be replaced if a malfunction occurs. Page 1

4 SPECIFIC JOB DATA. THE FOLLOWING PAGES WILL PROVIDE DATA FOR THIS SPECIFIC JOB, SUCH AS: BURNER MATERIAL LISTS WIRING DIAGRAM FUEL SYSTEM MATERIAL LIST Page 2

5 BURNER SPECIFICATIONS MODEL C 4 HIGH FIRE MBH BURNER MODEL MAX MIN LOW FIRE MBH GAS PRESSURE INCH W.C GAS TRAIN CONNECTION MOTOR MIN N P N P HP POWER SUPPLY AMPS. 115/1/60 C4-N ¾ ¾ 1/3 115/1/ C4.1-N ¾ ¾ 1/3 115/1/ C4.5-N ¾ ¾ 1/3 115/1/ FOR PROPANE. SAME FIRING RATE. SUFFIX P REPLACES N. MOTOR OPTIONS INCLUDE. 3 PHASE. TENV. AND 40 DEGREE BEARINGS. Page 3

6 BURNER MODEL DESIGNATION BURNER MODEL & SIZE: C4.1-N-03-H4.07 FUEL: N-NATURAL GAS P-PROPANE MOTOR HORSEPOWER: 03-1/3 HP GAS SYTEM: (See Gas Systems) GAS TRAIN SIZE: 07-3/ Page 4

7 INSTALLATION INSTRUCTIONS GENERAL The equipment shall be installed in accordance with the Provincial Installation Requirements, or in their absence, the most recent edition of Can/CGA-B149 installation code shall prevail. The heat transfer surfaces of the furnace or boiler should be cleaned before the burner is mounted. Consult your local gas utility company regarding any special requirements in the preparation of the furnace or boiler. VENTING REQUIREMENTS Flue pipe, double acting barometric damper, draft hood, or vent should not be smaller than recommended by the furnace or boiler manufacturer. The size is typically represented by the dimension of the smoke outlet. If existing flue pipe is used, it must be cleared of all soot and other deposits. GAS REQUIREMENTS Maximum inlet pressure to gas train must not exceed 14 W.C. for Natural Gas or 11 W.C. for LP Gas. For maximum capacity, natural gas minimum supply pressure must be 7 W.C. for C4.1 and C4.5 models, and 4 W.C. for C4 models. In any case, the gas pressure indicated on the firing rate label of the burner must prevail. COMBUSTION AIR SUPPLY The boiler room in which the burner is located must be provided with an adequate fresh air supply to assure proper combustion. The installation code Can/CGA-B149 specifies these requirements. WIRING The burner is prewired at the factory as far as practical. Refer to burner wiring diagram for complete wiring information and study thoroughly before making any connections. Make sure all connections on the flame safeguard base are tight, as they may have been loosened during shipment. Power to the burner must be 120 volts. All wiring, including electrical ground, must be done in accordance with Local Code requirements, or in the absence of local codes, with the Canadian Electric Code, CSA C22.1. Burner electric power should be provided from a separate fused disconnect switch located in the Boiler Room. BURNER GASKET Attach a rope gasket or sheet gasket to the burner mounting flange to prevent leakage of combustion gases into the Boiler Room. BURNER MOUNTING Attach burner to the boiler frontplate by firmly tightening nuts on the mounting studs or clamps so that a rigid installation is accomplished. Make sure burner is level before tightening clamps. Support burner housing to base or floor. Provide a minimum clearance of 30 around the burner for proper servicing. FLAME SAFEGUARD A manufacturer s instruction manual on the flame safeguard is included separately in this manual. Page 5

8 STARTING THE BURNER When starting the burner, open the manual gas shut-off valve, turn on the power and adjust the thermostat to the desired setting. This burner is equipped with interlocking safety devices. In the event of a flame failure or combustion air blockage, the burner will lock out. To restart, read the instructions on the flame safeguard or push the reset button, depending on the flame safeguard model. CLOSE DOWN PROCEDURES When closing the burner down for an extended period, turn off the power and close the manual gas shut-off valve. EMERGENCY PROCEDURES shut-off valve. In case of emergency turn off all power and close the manual Page 6

9 GAS PIPING. The gas control size furnished and the minimum gas pressure required at the inlet to the controls is shown in the Burner Material List contained in the manual shipped with the burner. Gas piping should be sized to provide the required minimum pressure at the main manual shutoff when operating at the maximum input. Consult your local utility on any questions regarding gas pressure, piping pressure drop allowable and local piping requirement. Gas piping should be installed in accordance with the installation code for gas burning appliances and equipment, CAN/CGA-B149, and any other local codes that may apply. All gas piping shall be tested after installation with air pressure or inert gas in accordance with the above-mentioned code. The installer shall identify the main manual shut-off valve. Page 7

10 COMBUSTION CHAMBER. The C burner is an Inshot design burner. It does not depend on refractory for its flame retention or combustion efficiency. Although refractory has a positive effect on combustion and therefore flame length. The boiler refractory primarily serves to protect those parts of the boiler that are exposed to excessive heat. The following combustion chamber illustrations are general in nature and show approximate chamber dimensions and recommended type and thickness of insulating materials. CAUTION It is the installing contractors responsibility to include and provide expansion joints, refractory supports, wall ties, etc as may be required for a proper installation. Consult your refractory supplier for contraction details and requirements for these items. The burner head must be wrapped with high temperature rope before the plastic refractory is put in place. Seal between the burner mounting flange and boiler front plate with high temperature rope gasket. RECOMMENDED FIREBOX DIMENSIONS 100 FIREBOX DIMENSIONS IN INCHES Length Width BURNER CAPACITY IN MBH Page 8

11 FIREBOX BOILER fired through front of base. FIREBOX BOILER fired through door. SCOTCH MARINE BOILER. AIR HEATER Page 9

12 TEMPLATE DIMENSIONS MOUNTING FLANGE OUTLINE (4) 3/8 STUDS B A B BURNER MODEL BURNER HEAD A B DIAMETER C C C ALL DIMENSIONS ARE IN INCHES. Page 10

13 BURNER PRESTART-UP CHECKLIST CAUTION This manual has been prepared as a guide in burner start- up operations. It is written for the startup specialist who are thoroughly qualified both by training and experience. 1. GENERAL - The following data is pertinent to the burner start-up and should be carefully studied before any attempt to operate the burner is made. The following is a part of the manual shipped with the burner. Burner Material List Burner Wiring Diagram Flame Safeguard/Ignition Module Bulletin Misc. Manufacturer's Data on Controls, Valves, Regulators, etc. NOTE The above cited manual is ONE OF A KIND in that it contains material covering your SPECIFIC burner. To replace it, considerable time, special handling and significant costs are involved. Accordingly, it should be handled with care and kept in a location free of dust and moisture. 2. IDENTIFICATION OF CONTROLS - Review the burner wiring diagram and operating sequence. Study these items and identify the various controls. NOTE Do not proceed with start-up unless all applicable check list items in Part IV and preliminary adjustment requirements in Part V have been satisfied. Be certain combustion chamber, flues, and surrounding areas are free of GAS accumulations, and other combustibles such as paint thinners, cleaning solutions, etc. An explosimeter (Mine Safety Appliances Co. Model No. 2A or equivalent) may be used to make this determination. WARNING 3. REVIEW BURNER MATERIAL LIST IN THE INSTRUCTION MANUAL AND NOTE THE FOLLOWING INFORMATION: A. Firing rate (MBTU) B. Cubic feet of gas per hour (CFH) C. BTU per cubic foot (BTU/CF) D. Required gas pressure at control inlet (inches W.C.) E. Required gas pressure at manual leak test valve (inches W.C., taken at port of valve.) The above information is pertinent to setting up the burner. Page 11

14 LINKAGE ADJUSTMENT: High/Low Control or On/Off Control with Low Fire Start With the burner power off, loosen the linkage rod in the damper arm ball joint connector. Move the damper arm so that the low fire stop is between the 25 and 50% mark on the damper quadrant. Tighten the linkage rod and move the actuator arm against the spring action to the full open position. The low tire stop should indicate between 75% and 100% on the damper quadrant. If the damper arm travels too much, move the linkage arm away from the damper shaft on the damper arm and repeat above-mentioned procedure. If the damper arm travels not far enough, move the linkage arm to the damper shaft on the damper arm. Start the burner. In high fire, take a meter reading and if necessary, readjust the outlet pressure of the regulator. Now check the excess air and readjust the damper position by readjusting the linkage rod. Mark the damper position on the quadrant. In low fire position, take a meter reading and readjust the low fire position on the actuator (see attached manufacturers instructions). Check the excess air. If damper needs readjustment in low fire, go back to high fire and readjust the position of the ball joint connector. Again, towards the shaft means more closed in low fire position and away from the shaft means more open n low fire position. Check high fire and low fire positions again and adjust low fire stop. Page 12

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16 INITIAL START UP 1. Make sure burner power switch is off and manual main and pilot valves are closed. 2. Make proper settings on limit controls. 3. Open the fire door of the boiler. 4. Turn on burner power switch momentarily to check blower rotation. 5. Check gas tightness of main and pilot safety shut off valves (if used) by connecting a pressure gauge to the pressure tap located between the safety shut-off valve and the test-firing valve. When the test firing valves are closed and the manual shut-off valves are opened, no pressure rise should show on the pressure gauge. 6. Open the air damper approximately 3/4 for on/off burners. For H/L and modulating burners, open-air damper 1/4 in low position of the actuator lever, allowing the damper to travel to 3/4 in high position of the actuator lever. (These settings are factory made). Turn on the burner switch, while the main and pilot gas firing valves are closed. After the prepurge the ignition transformer and solenoid valves will be energized. Observe the ignition spark for proper location and firmness. After the trial for ignition time, the ignition transformer and solenoid valve are de-energized and the burner will lock out. 7. Open the pilot test firing valve and turn on the burner switch, while the manual main shut-off valve stays closed. After the prepurge, the ignition transformer and the pilot solenoid valve are energized. Observe the pilot flame and if necessary, adjust the pilot pressure regulator to obtain a stable flame with the highest steady flame signal. For flame signal readings, see attached flame safeguard manual. With the main manual shut-off valve still closed, the flame safeguard will lock out after approximately 10 seconds, only with high/low and modulating burners, which use an interrupted pilot. Repeat the ignition cycle a few times to ensure a fast igniting and stable pilot flame. 7A. With direct spark ignition test and observe the electric spark, with a closed main manual shut off valve. In this case, the flame safeguard will tolerate only 4 seconds for observation of the spark, before it locks out. 8. Open the main manual shut-off valve and set the high/low limit switch and the modulating controller so that after establishing a main flame, the burner will travel to high fire. Start the burner, in high fire, check the manifold pressure with the required pressure for the firing rate, (see suggested inspection list) and if necessary, adjust pressure regulator. Readjust the damper if fire looks too lean or too rich. 9. **Close boiler firing door. Take a gas meter reading and readjust manifold gas pressure if necessary. Take a CO2 or 02 and a CO reading. CO2 should be between 8.5 and 9.5% and 02 should not be more than 5%, both with a maximum CO reading of.04%. Readjust air damper accordingly. **Important Note: To be used as guidelines only. Readings will vary according to actual conditions and equipment being fired. Page 14

17 10. With high/low and modulating burners, mark the high air damper position and set the high/low limit control or modulating control so that the burner travels to low position. Visually adjust the input adjuster on the main gas shut-off valve actuator if low fire is too rich or too lean. Take a gas meter reading and readjust the input adjuster according to the required low fire input, which will be about 1/3 of the high firing rate but not less than indicated in the specifications table. In order to keep the high fire setting unchanged when adjusting the low fire air damper position, drive the burner to high fire, change the positioning of the linkage as indicated in Low Fire Adjustment, drive the burner back to low fire and check the CO2 or 02 readings. Repeat this procedure until a satisfactory setting is obtained. 11. Make sure all linkage connections are tight and check the readings in high and low fire 12. Reset controller and limits to their desired settings. CAUTION Do not adjust flame visibly. Instruments are the only safe and reliable means to determine the proper adjustments. Page 15

18 BURNER SAFETY CHECK 1. Start and stop burner several times to insure proper operation. 2. Check operation of combustion safeguard control by simulating a flame failure, making certain the burner locks out in safety within the proper time. See flame safeguard/ignition module instructions for procedure. 3. Check operation of the air flow switch, making certain fuel valve closes when the air flow diaphragm switch open. 4. Set the high limit control 2 to 3 psi or 10 degrees F. to 15 degrees F. higher than the desired operating pressure or temperature. Set the operating control pressure or temperature higher than the high limit control for this test. Permit burner to run until desired HIGH LIMIT pressure or temperature is indicated and then adjust high limit control, if necessary, to shut off the burner at the desired high limit pressure or temperature. 5. Reset operating control to desired pressure or temperature. Permit burner to run until it is shut off by the operating control. Adjust operating control, if necessary until it causes burner to stop and start within desired range. 6. With the burner running, open the blow-down valve on the low water cutoff (if used). The burner should shut off immediately. The burner should restart automatically when the proper level of water in the low water cutoff is reestablished. 7. Conduct minimum pilot turn down test, reduce gas pressure to pilot with manual shutoff cock to the point pilot flame is extinguished or fails to prove. Increase gas flow slightly. Main flame must be ignited with this pilot flame. 8. The following readings should be taken and recorded after final adjustments have been made. A Burner input (CFH gas) B. Percent C02 or 02 C. CO indication D. Stack temperature E. Firebox pressure F. Fuel pressure (in. W.C.- gas) (main and pilot) G. Voltage to burner 9. Give instruction to owner (operator). WARNING Should overheating occur : (1) Shut off the manual gas control(s) to the burner. (2) Do Not shut off the control switch to the pump or blower. Page 16

19 GENERAL MAINTENANCE 1. Make certain combustion chamber and flues are purged of any unburned fuel before attempting to start burner following an OFF period due to any burner problems. 2. Always follow the Burner Operating Instructions in turning the burner OFF or ON. 3. Make certain that all electrical connections are secure, including the flame safeguard/ignition module relay mounting connections. 4. Maintenance of flame safeguard/ignition module control, and other such burner components, should be preformed in accordance with instructions contained in the manufacturer s bulletin. YEARLY MAINTENANCE Preferable before start of heating season. 1. Remove blower motor and blower wheel assembly and clean. 2. Remove gas manifold assembly and clean. 3. Remove pilot/sensor and clean. 4. Clean all inside surfaces of blower scroll. 5. Make repairs to combustion chamber. 6. Check operation of all limit and operating controls. 7. Tighten all screws holding components and conductors. 8. Check combustion. PREVENTIVE MAINTENANCE 1. Visually inspect for dirt deposits on blower wheel. 2. Check that blower wheel is not loose on motor shaft. 3. Check that air flow switch is working properly. 4. Check the combustion chamber for loose bricks and cracks. 5. Oil both bearings of blower motor as directed by decal located on motor housing. 6. Always keep cover on control cabinet, except during servicing. 7. Check operation of flame safeguard/ignition module as per starting instructions. 8. Check limit and operating control Page 17

20 BURNER DIMENSIONS D B GAS CONNECTION "L" J 4 x (K) C A M F E H G BURNER MODEL A B C D E F G H J K L M C ¼ 12-1/2 5 1/2 or /2 9-1/2 5-5/8 1/2 3/4 7 C ¼ 12-1/2 5-1/2 or /2 9-1/2 5-5/8 1/2 3/4 7 C /2 4 ¼ 12-1/2 5-1/2 or /2 9-1/2 5-5/8 1/2 3/4 7 AIR DAMPER GAS INLET MOUNTING FLANGE HOUSING COVER BURNER HOUSING AIR FLOW SWITCH BLAST TUBE ASSEMBLY IGNITION TRANSFORMER AIR INLET SCREEN BLOWER WHEEL FAN MOTOR Page 18

21 C4 BURNER ASSEMBLY IGNITION ELECTRODE 1/16" TO 1/8" 3.875" 1" 1-3/4" RETENTION PLATE GAS MANIFOLD GP COMBUSTION EQUIPMENT INC. CAMBRIDGE, ONTARIO TITLE MODEL PR DRAWER SETTINGS SIZE DATE A SEPT 8, 08 DWG NO. C4 BURNER HEAD ASSY BY: RR SCALE: 1 : 1 ALL DIMENSIONS ARE INCHES SHEET: 1 OF 1 REV A C4 BURNER ASSEMBLY IGNITION ELECTRODE 1/16" TO 1/8" 3.875" 1" 1-3/4" RETENTION PLATE GAS MANIFOLD GP COMBUSTION EQUIPMENT INC. CAMBRIDGE, ONTARIO TITLE MODEL ST DRAWER SETTINGS SIZE DATE A SEPT 8, 08 DWG NO. C4 BURNER HEAD ASSY BY: RR SCALE: 1 : 1 ALL DIMENSIONS ARE INCHES SHEET: 1 OF 1 REV A

22 P/N 033 MAIFOLD TUBE T68-7C P/N FR/ELECTRODE HOLDER P/N 042 ORIFICE RETENTION PLATE P/N 036 AIR SCOOP P/N 029 MANIFOLD BLOCK P/N 044-? NOZZLE P/N 035 FOR 5-1/2" NOSE P/N FOR 8" NOSE PILOT TUBE FLAME ROD/ELECTRODE HOLDER X 1/2" BALL RETAINING SCREW P/N 043 PILOT DEFLECTOR NY CHECK BALL FW CHECK WASHER P/N FOR 5 1/2" NOSE P/N FOR 8" NOSE NOZZLE TUBE GP COMBUSTION EQUIPMENT INC. CAMBRIDGE, ONTARIO TITLE MANIFOLD ASSEMBLY PR SIZE DATE A SEPT 8, 08 DWG NO. 032 BY: RR SCALE: 1 : 1 ALL DIMENSIONS ARE INCHES SHEET: 1 OF 1 REV A P/N 033 MANIFOLD TUBE T68-7C P/N ELECTRODE RETENTION HOLDER PLATE P/N 042 ORIFICE FLAME ROD P/N 029 MANIFOLD BLOCK ELECTRODE P/N 044 NOZZLE FLAME ROD/ELECTRODE HOLDER P/N FOR 5 1/2" NOSE P/N FOR 8" NOSE NOZZLE TUBE GP COMBUSTION EQUIPMENT INC. CAMBRIDGE, ONTARIO TITLE MANIFOLD ASSEMBLY ST SIZE DATE DWG NO. BY: A SEPT 8, RR SCALE: 1 : 1 ALL DIMENSIONS ARE INCHES 1 OF 1 SHEET: REV A

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26 No. QTY DESCRIPTION GP PART No. OR VENDOR No. 1 1 COMBUSTION HEAD SEE BELOW 4 1 NOZZLE SEE BELOW 6 1 ORIFICE (NOT SHOWN) SEE MAT. LIST 9 1 HOUSING WELD ASSY AIR DAMPER ASSY DAMPER SHAFT TOP COVER HOUSING AIR INLET CONE SEE BELOW 15 1 MOTOR MOUNTING PLATE RETENTION PLATE ASSY MANIFOLD PILOT TUBE ASSY SEE BELOW 20 1 ELECTRIC MOTOR 1/3 HP-56C IGNITION TRANSFORMER Q652B AIRFLOW SWITCH AFS-A 26 1 LINKAGE ARM CONTROL QUADRANT SIGHT GLASS SIGHT GLASS RETAINER SIGHT GLASS GASKET IGNITION ELECTRODE FLAME ROD JUNCTION BOX K 45 1 BLOWER WHEEL SEE BELOW 46 2 ELECTRODE HOLDER T68-7C 47 1 AIR INLET COVER PLATE HOUSING COVER PLATE ELECTRODE HOLDER PRE-MIX SCOOP MANIFOLD ASSEMBLY ITEM 1) 5.5" NOSE 1) 8" NOSE 4) NOZZLE 14) CONE 19) TUBE 5.5" 19) TUBE 8" 45)WHEEL C A C B C C GP COMBUSTION EQUIPMENT INC. CAMBRIDGE, ONTARIO TITLE MODEL C4,C4.1,C4.5 CUSTOMER:TYPICAL SIZE DATE A SEPT 1, 04 DWG NO. ML-4-TYP BY: RR SCALE: NTS ALL DIMENSIONS ARE INCHES SHEET: 1 OF 1 REV A