Table Of Contents

Profire K
Burner
Light Oil, Gas, or Combination
Installation
Operation
Maintenance

Manual Part No. 750-282 12/2009

K/SERIES
Installation,
Operation,
and
Service Manual

WARNING
ONLY FACTORY AUTHORIZED BURNER
SERVICE PERSONNEL SHOULD START UP,
ADJUST, OR SERVICE THIS EQUIPMENT.

750-282
12/09
 K SERIES TABLE OF CONTENTS

PAGE
SECTION 1. INTRODUCTION
A. GENERAL INFORMATION .............................................. 3
B. DESCRIPTION................................................................. 3
C. OPERATING CONTROLS ............................................... 3
D. FLAME SAFEGUARD CONTROLS................................. 3
E. COMBUSTION AIR HANDLING SYSTEM....................... 4
F. OIL SYSTEM ................................................................... 4
G. PILOT SYSTEM............................................................... 4
H. GAS SYSTEM.................................................................. 4
SECTION 2. INSTALLATION
A. DRAFT CONDITIONS.......................................................7
B. COMBUSTION AIR SUPPLY ............................................7
C. COMBUSTION CHAMBER DESIGN ................................7
D. BURNER INSTALLATION .................................................7
E. GAS PIPING .................................................................... 9
F. FUEL OIL PIPING ............................................................. 9
G. INSTALLATION CHECKLIST........................................... 14
SECTION 3. STARTING AND OPERATING
A. PREPARATION FOR INITIAL START-UP ....................... 15
B. FIRING PREPARATIONS .............................................. 15
C. SEQUENCE OF OPERATION ........................................ 16
D. ELECTRICAL INTERFERENCE TEST ........................... 16
E. START-UP AND OPERATION ........................................ 17
F. NORMAL OPERATION.................................................... 19
G. SHUTDOWN.................................................................... 19
PAGE
SECTION 5. MAINTENANCE
A. GENERAL ........................................................................ 28
B. CONTROL SYSTEM ........................................................ 28
C. GAS SYSTEM.................................................................. 28
D. OIL SYSTEM ................................................................... 29
E. DRAWER ASSEMBLY ..................................................... 29
F. IGNITION ELECTRODE, CABLE, AND PILOT ............... 29
G. FLAME SCANNER .......................................................... 29
H. BURNER MOUNTING INSPECTION .............................. 29
I. EXTENDED SHUTDOWN ................................................ 29
J. MAINTENANCE FLOW CHART ...................................... 30
SECTION 6. TROUBLE SHOOTING
BURNER DOES NOT START .............................................. 31
NO IGNITION ....................................................................... 31
PILOT BUT NO MAIN FLAME .............................................. 32
BURNER STAYS IN LOW FIRE ........................................... 32
SHUTDOWN DURING FIRING..........................................32-33
MODULATING MOTOR DOES NOT OPERATE .................. 33
WARRANTY POLICY........................................................35-36
START-UP AND SERVICE REPORT ................................... 37
PRODUCT SATISFACTION SURVEY ................................. 38

SECTION 4. ADJUSTMENTS
A. GENERAL ....................................................................... 20
B. COMBUSTION ADJUSTMENTS OIL AND GAS ............. 20
C. GAS PILOT ADJUSTMENT ............................................ 21
D. DIRECT SPARK OIL PILOT ADJUSTMENT ................... 21
E. BURNER SETTINGS ...................................................... 21
F. PILOT TURN DOWN TEST ............................................. 23
G. LOW-HIGH OFF BURNER ADJUSTMENTS................... 23
H. FULL MODULATION BURNER ADJUSTMENTS ........... 25
 OPERATING PRECAUTIONS
This operating manual presents information that will help to properly operate and care
for the equipment. Study its contents carefully. The unit will provide good service and
continued operation if proper operating and maintenance instructions are followed. No
attempt should be made to operate the unit until the principles of operation and all of
the components are thoroughly understood. Only trained and authorized personnel
should be allowed to operate, adjust or repair this equipment.

If you are operating a burner(s), it is your responsibility to ensure that such operation
is in full accordance with all applicable safety requirements and codes.

Placed on all CB Prof re burners are warning or caution labels designed to inform the
operator of potential hazards and stress important information.

These symbols and their meanings are as follows:

WARNING
FAILURE TO INSTALL AND OPERATE THIS EQUIPMENT IN ACCORDANCE WITH THE
MANUFACTURERS RECOMMENDED INSTRUCTIONS AND INDUSTRY STANDARDS AND
PRACTICES CAN RESULT IN FIRE, EXPLOSION, PROPERTY DAMAGE AND/OR PER-
SONAL INJURY !! READ THIS MANUAL IN ITS ENTIRIETY PRIOR TO ANY ATTEMPT TO
COMMISSION THIS EQUIPMENT. INSTALLATION, STARTUP, OPERATION AND MAINTE-
NANCE OF THIS EQUIPMENT MUST BE PERFORMED ONLY BY FACTORY AUTHORIZED,
EXPERIENCED AND QUALIFIED PERSONNEL.

WARNING
HAZARD OF ELECTRIC SHOCK !!! MORE
THAN ONE DISCONNECT MAY BE RE-
QUIRED TO DISCONNECT ALL POWER
TO THIS PANEL. SERIOUS PERSONAL
INJURY OR DEATH MAY RESULT.
WARNING
READ PRODUCT MANUAL AND FULLY
UNDERSTAND ITS CONTENTS BEFORE-
ATTEMPTING TO OPERATE THIS EQUIP-
MENT. SERIOUS PERSONAL INJURY OR
DEATH MAY RESULT.

WARNING
TO AVOID PERSONAL INJUR Y FROM
MOVING PARTS, SHUT OFF ALL ELEC-
TRICAL POWER BEFORE SER VICING
THIS EQUIPMENT.
CAUTION
PROVIDE SUPPORT FOR THIS PANEL
TO PREVENT DAMAGE TO THE ELEC-
TRICAL COMPONENTS.

CAUTION
ONLY FACTORY AUTHORIZED BURNER
SERVICE PERSONNEL SHOULD START-
UP, ADJUST, OR SERVICE THIS EQUIP-
MENT.
CAUTION
AFTER FINAL FUEL INPUT ADJUST-
MENTS ARE MADE, VERIFY FUEL IN-
PUT BY METER IF POSSIBLE.

1
Further warning and caution references have been
made in this manual and should be adhered to for RATED BURNER INPUT
smooth operation of the burner. SIZE MBTU/HR US GPH
13 1,260 9.0
This symbol precedes information
17 1,680 12.0
WARNING which, if disregarded, may result
in injury to the user of the burner 21 2,100 15.0
or to others. 25 2,520 18.0
This symbol precedes information 30 2,940 21.0
CAUTION which, if disregarded, may result 34 3,360 24.0
in damage to the burner.
42 4,200 30.0
This symbol precedes information 54 5,250 37.5
NOTE which is vital to the operation or 63 6,300 45.0
maintenance of the burner.
84 8,400 60.0
Model designations are based on the type of fuel(s) to 105 10,500 75.0
be f red and the amount of furnace pressure to be over-
125 12,600 90.0
come. Burner size is based on f ring rate (rated input in
BTU/HR). 145 14,700 105.0
* Gas input based on natural Gas at 1,000
MODEL FUEL ATOMIZATION Btu/cu.ft. and 0.60 specif c gravity.
KG GAS ** Oil input based on 140,000 Btu/gal.
KL #2 OIL PRESSURE *** Refer to burner nameplate data for correct
KLG #2 GAS/OIL PRESSURE manifold pressures.

EXAMPLE: Model number on nameplate is

KLG-42, indicating it is a combination No. 2 oil and Gas
burner with input rated at 4,200 MBTU per hour, against
furnace pressures up to 1.0 W.C.

BURNER SIZE AND RATED FURNACE PRESSURE

K/BURNER:
SIZE 1 - K13 to 25 0.75 W.C.
SIZE 2 - K30 to 42 1.5 W.C.
SIZE 3 - K54 to 84 3.0 W.C.
SIZE 4 - K105 to 145 4.0 W.C.

THE INSTALLATION OF A BURNER SHALL BE IN ACCORDANCE WITH THE REGULATIONS OF AUTHORITIES

HAVING JURISDICTION. THE EQUIPMENT MUST BE INSTALLED IN ACCORDANCE WITH APPLICABLE
LOCAL, STATE OR PROVINCIAL INSTALLATION REQUIREMENTS INCLUDING THE NATIONAL ELECTRICAL
CODE (NEC) AND ASSOCIATED INSURANCE UNDERWRITERS.

OIL AND GAS BURNING EQUIPMENTS SHALL BE CONNECTED TO FLUES HAVING SUFFICIENT DRAFT AT
ALL TIMES, TO ASSURE SAFE AND PROPER OPERATION OF THE BURNER.

THE K SERIES BURNERS ARE DESIGNED TO BURN EITHER GAS OR LIGHT OIL No.1 OR 2 AS DEFINED BY
ASTM D396-1978 SPECIFICATIONS.
DO NOT USE GASOLINE, CRANKCASE OIL, OR ANY OIL CONTAINING GASOLINE.

2
 SECTION 1
INTRODUCTION
A. GENERAL INFORMATION Gas position: Selects gas as the f ring fuel
CB Pro f re K/Series burners are assembled, wired and Off position: Burner off
tested at the factory. They are listed by the Underwriters Oil position: Selects oil as the f ring fuel
Laboratory, cUL, CSD-1, I.R.I., F.M., and other regulatory
agency control options are available. 3. CONTROL CIRCUIT BREAKER
Supplementary low overcurrent protection only.
The operator of this equipment must be familiar with the No larger than 15 amps.
individual functioning of all controls to understand the
operations and procedures described in this manual, and 4. AUTO-MANUAL MODULATION SELECTOR
supplementary instructions provided with optional controls. SWITCH
Identify and locate each item in the illustrations as they are Auto Position: Selects boiler modulation control. In
described in the following sections. this position, the burner will operate automatically in
response to load demand.
Manual Position: Selects 135 ohm potentiometer
CAUTION for manual modulating control.

ONLY F ACTORY AUTHORIZED BURNER 5. MANUAL MODULATING CONTROL 135 ohm

SERVICE PERSONNEL SHOULD START-UP, (For full modulation burners only) Increases or
ADJUST, OR SERVICE THIS EQUIPMENT decreases the burner f ring rate manually.

6. SIGNAL LAMPS.
B. DESCRIPTION
a. POWER ON (white) illuminates when the control
CB Prof re K/Series burners are designed to operate with
circuit is energized (powered).
gas and light oil. K burners are speci f cally designed to
b. IGNITION (amber) illuminates when the ignition
operate in scotch marine type boilers. The burners are
transformer is powered, and pilot valve is
designed for automatic, unattended operation except for
energized (opened).
periodic inspection and maintenance. The control panel
c. MAIN FUEL (green) illuminates when the main
components require little attention except for occasional
fuel valve or valves are energized (open).
cleaning.
d. FLAME FAILURE (red) illuminates when the
f ame safeguard system fails to detect pilot or
The burners are available in the following conf guration:
main f ame.
SIZE 1 - K13-25 Low-High-Off
7. MODULATING MOTOR
(Optional: Low-High-Low, Full Modulation)
Operates the air damper and fuel rate valves through
a linkage system to adjust air-fuel ratios under all load
SIZE 2 - K30-42 Low-High-Off
conditions.
(Optional: Low-High-Low, Full Modulation)
8. IGNITION TRANSFORMER
SIZE 3 - K54-84 Full Modulation
Provides high voltage spark for ignition of gas pilot or
main f ame direct spark models.
SIZE 4 - K105-145 Full Modulation
D. FLAME SAFEGUARD CONTROLS
The f ame safeguard controls the operating sequence of the
C. OPERATING CONTROLS - PANEL
combustion system (prepurge, pilot, f ring and shutdown).
The control panel contains a f ame safeguard program-
The f ame safeguard programmer incorporates a f ame
ming control, motor relays (starters), and terminal strips
sensing cell (scanner) to shut down the burner in the event
mounted internally on a panel subbase. Lights, switches,
of pilot f ame or main f ame failure. Other safety controls
and a control circuit breaker are mounted externally on the
shut down the burner based on sequence of operation as
panel as indicated below.
shown in the manufacturers f ame safeguard manual.

1. ON-OFF BURNER SWITCH

2. FUEL SELECTOR SWITCH - Gas - Off - Oil

3
E. COMBUSTION AIR HANDLING SYSTEM shipped loose with burner.
1. MOTOR AND BLOWER - The impeller is directly driven
by the motor at 3450 rpm. Combustion air is supplied by OPERATION
a heavy duty balanced backward curved impeller . The Fuel oil is delivered to the fuel unit, either by gravity , fuel
impeller remains free from dirt accumulation. unit suction, or by a circulating pump, through a fuel oil
f lter. Pressurized fuel returns to the storage tank until the
2. AIR VOLUME REGULATOR - The air damper is located two solenoid valves open. On direct spark ignited burners,
in the air inlet housing. Low-high-of f, low-high-low or full (KL-13 to 42) ignition occurs when the oil valves open.
modulation burners have the damper directly driven by the Where gas pilots are provided (Models KG and KLG), the
modulating motor. oil valves open after the pilot is proven. Oil input rate is
controlled by the oil metering valve, which varies the f ow to
3. COMBUSTION AIR PROVING SWITCH - A pressure meet load demands. The low-f re positions bypass oil back
sensitive switch actuated by air pressure created by the to the storage tank. At high-f re, the metering valve is in the
blower fan. Contacts close to prove combustion air f ow. closed position. The metering valve and the air damper are
positioned simultaneously by the modulating motor.

OPERATION G. PILOT SYSTEM

Air from the impellerf ows through the blast tube and baf f e Oil only models KL-13 to 42 are supplied with direct spark
to mix with fuel in the ignition zone. Combustion fair ow rate ignition. Models KL-54 to 145 are supplied with a gas pilot
is determined by the position of the air regulating blades at system. Gas and combination Gas-Oil models are supplied
the inlet of the impeller. Linking the air f ow with fuel f ow with a gas ignition system. The standard pilot gas train
provides eff cient combustion at all f ring rates. consists of a manual shutoff cock, a gas pressure regulator
and a solenoid operated gas shutoff valve.
F. OIL SYSTEM
Models KL - KLG are high pressure atomizing burners usingH. GAS HANDLING SYSTEM
fuel pressure for atomization. Atomized fuel is discharged Depending upon the requirements of the regulating author-
from the nozzle as a f ne conical spray. ity, the gas control system and gas train may consist of
some, or all, of the following items:
1. FUEL UNIT - Direct driven from the blower motor with
a f exible coupling at 3450 rpm, and set for 300 psi opera- MAIN GAS TRAIN COMPONENTS
tion, fuel unit is two stage (two sets of gears) and must be 1. GAS VOLUME VALVE - The butterf y type valve is po-
installed for a two pipe installation, one suction and one sitioned by linkage from the modulating motor and controls
return line. Separately driven oil pumps are available as the rate of f ow of gas.
option to the standard arrangement.
2. MAIN GAS VALVES - Electrically operated safety shutof f
2. NOZZLE - The nozzle meters oilf ow delivering a speci- valve(s) that open to admit gas to the burner . Standard
f ed amount at a specif c pressure. Fuel pressure (mechani- U.L. burners include:
cal) atomizes oil in a f ne conical spray pattern from the -Models: 13-25; Diaphragm gas valve and one safety
nozzle orif ce. The burner is supplied with nozzle(s) tof re to solenoid valve
its maximum rate unless a different f ring rate was specif ed. -Models: 30-42; One motorized gas valve w/proof of
Return f ow nozzle(s) are used on the size - 4 burners. closure
-Models: 54-145; One motorized gas valve w/proof of
3. NOZZLE ADAPTOR - The nozzle adaptor provides the closure and one safety solenoid valve
means for connecting fuel lines with the nozzle.
3. MAIN GAS REGULATOR - Regulates gas train pressure
4. OIL SOLENOID VALVES - Two normally closed (N.C.) to specif ed pressure required at the burner manifold. Input
and one normally open (N.O.) solenoid valves are part of is set by main gas pressure regulator adjustment.
the oil system on LO-HI-OFF and LO-HI-LO burners. The
two N.C. valves provide positive shut of f of fuel oil while 4. MAIN GAS COCKS - Used for manual shutof f of the
the one N.O. valve cycles the burner to high f re when gas supply upstream of the pressure regulator. A second
closed. shutoff cock downstream of the main gas valve(s) provides
a means of testing for leakage through the gas valve(s).
5. OIL METERING VALVE - The f ring rate is controlled by
an adjustable metering valve in the return line. At low-f re, 5. HIGH GAS PRESSURE SWITCH. (Models 30-145)
the metering valve is open, and is closed at high-f re. A pressure actuated switch that remains closed when gas
pressure is below a selected setting. Should the pressure
6. OIL FILTER - Prevents foreign matter from entering rise above the setting, the switch contacts will open causing
the burner oil system. This item is provided optional and main gas valve(s) to close. This switch requires manual

4
reset after being tripped. A normally open vent valve, if required, is located between
the two automatic gas valves. This valve is shut when
6. LOW GAS PRESSURE SWITCH. (Models 30-145) the automatic gas valves are open. When the automatic
A pressure actuated switch that remains closed when gas valves are closed, the vent valve is open for venting gas
pressure is above a selected setting. Should the pres- to the outside, should any be present.
sure drop below this setting, the switch contacts will open,
causing main gas valve(s) to close. This switch requires
manual reset after being tripped. NOTE
OPERATION GAS TRAIN COMPONENTS UP-
Metered gas f ows through the main gas shutof f cock, STREAM OF THE BUTTERFL Y
through the pressure regulator to the automatic gas valves VA LV E A R E S H I P P E D L O O S E TO
and butterf y valve to the gas manifold.The butter f y gas BE MOUNTED BY THE INST ALLER.
valve modulates f ow to burner input demand. The but-
terf y valve is positioned through mechanical linkage by
the modulating motor. The air control damper is positioned
simultaneously by the modulating motor. The automatic
NOTE
gas valve(s) cannot be energized unless the combustion PILOT GAS SUPPLY CONNECTION MUST
air proving switch is closed.The low and high gas pressure BE UPSTREAM OF THE MAIN GAS PRES-
switches must be closed to prove proper gas pressure. SURE REGULATOR.

GAS PILOT LINE

BLOWER
MOTOR

GAS BUTTERFLY
IGNITION VALVE
TRANSFORMER
COMBUSTION
AIR SWITCH

OIL PUMP

MODULATING MOTOR
CONTROL PANEL
656-09610

Figure 1-1

5
 GAS MANIFOLD

MOUNTING FLANGE

NOZZLE BODY
& TIP
AIR BAFFLE

GAS ORIFICES

656-09611

Figure 1-2

6
 SECTION 2
INSTALLATION
A. DRAFT CONDITIONS BURNER COMBUSTION CHAMBER
A boiler or other heating vesself red with a K Series burner MODEL LENGTH WIDTH CL HEIGHT
does not depend on chimney draft for proper combustion
13 56 26 12
air. Combustion air is supplied by the burner forced draft
blower providing adequate air for any normal combustion 17 56 26 12
condition. 21 56 26 12
Since draft control is essential to maximum ef f ciency, 25 56 26 12
a draft regulator may be required when the vessel is con-
nected to a tall stack or where wind conditions may cause 30 62 30 13.5
erratic draft. Excessive furnace draft contributes to inef
f cient 34 62 30 13.5
burner operation. 42 62 30 13.5
Sealed boilers may be operated under positive f rebox
54 83 33 15
pressure within the capability of the burner.
63 83 33 15
B. COMBUSTION AIR SUPPLY 84 104 39 18.5
The space in which a burner operates must be supplied 105 128 39 18.5
with adequate fresh air for combustion and ventilation
purposes. Fresh air supply must meet or exceed all code 125 128 39 18.5
requirements. Consult with insurance carrier and/or local 145 128 39 18.5
authorities for specif c regulations. Figure 2-1

WARNING D. BURNER INSTALLATION

THE BOILER ROOM PRESSURE MUST BE
AT LEAST EQUAL TO THE OUTDOOR ATMO-
SPHERIC PRESSURE. WHERE F AN VENTILA-
TION IS USED, AIR MUST BE FORCED INT O
THE BOILER ROOM. NEVER EXHAUST AIR
FROM THE BOILER ROOM. ADJOINING AREAS
HAVING EXHAUST FANS MUST BE POSITIVILY
ISOLATED FROM THE BOILER ROOM.
C. COMBUSTION CHAMBER DESIGN
Suggested minimum combustion chamber dimensions
in Figure 2-1 are based on the rated capacity of the burner
. 3. Using insulating rope gasket, wrap rope on the inside
While these dimensions are typical for good practice,
satisfactory results may be achieved with modif cations to
suit some conditions. Factors such as fuel properties, total
combustion volume, and length off ame travel often make
f xed requirements impractical. When in doubt, consult the
facotry. Insulation should be provided between the burner
mounting f ange and the boiler adaptor plate.
Prepare the boiler front plate as follows:
1. Determine burner mounting height. Locate and scribe a
level horizontal centerline across the mounting face.
2. Locate and scribe vertical centerline. Be sure stud loca-
tions line up where studs will have full support. If they dont
or if opening is too large, a steel adapter plate, 3/8 mini-
mum may be welded or bolted in place. Suitable anchors
should be provided to hold refractory in place. Adapter
plate must be properly sealed (use insulating rope gasket
to prevent leakage of combustion gases.
of the bolt circle, looping rope around the four mounting
studs.
4. Set burner into position for mounting and tighten into
place. Size 1, 2 and 3 burners are provided with four lugs
to secure burner to front plate. Size 4 burners are equipped
with a four hole mounting f ange.

5. Permanently support the burner using the pipe support

connections. See Figure 2-2.
CAUTION
6. The space between the boiler refractory, water leg, or
GASKET MUST BE RESILIENT TO SEAL
f re tube and outside diameter of the blast tube must be
ANY UNEVEN AREAS BETWEEN THE
packed with plastic refractory, Kaiser Refractory Mono T-
BURNER FLANGE AND THE BOILER
Air Set or equal. Ram plastic refractory from front to rear,
FRONT PLATE TO PREVENT LEAKAGE OF
parallel to outside surface of blast tube. See Figure 2-3.
COMBUSTION GASES.

7
 SUPPORT BURNER HERE

Figure 2-2

(2) 1" INSULATING BLANKET

(KAO-WOOL, CERABLANKET, DURABLANKET)

ON ALL SCOTCH BOILERS REFRACTORY

2" BLOCK INSULATION PROTECTION MUST EXTEND AT LEAST
TUBE 2.50" PAST THE TUBE SHEET
SHEET
2.50" MIN.

PACK WITH PLASTIC REFRACTORY

BOILER FRONT PLATE (KAISER MONO T-9 AIR SET OR
EQUAL, RAM FROM FRONT TO REAR)
BURNER FLANGE

45
MIN.

WRAP WITH KAO-WOOL

(COAT BOTH SIDES WITH TROWLEZE)

1" GASKET OR ROPE

BURNER HEAD

BURNER MOUNTING DETAILS FOR SCOTCH MARINE BOILERS

Figure 2-3

8
E. GAS PIPING b. Length of suction line (feet).
Gas service and house piping must supply the quantity c. Diameter of the suction line.
of gas demanded by the unit at the pressure required at d. Number of f ttings.
the burner gas train inlet. Although the gear type pumps used on the H series burners
are capable of developing higher suction, it is not desirable
All piping must be in strict accordance with applicable to operate above 15 inches of mercury vacuum. If the
codes, ordinances and regulations of the supplying utility. vacuum is greater, f ow may be erratic.
In the absence of other codes, piping should be in accor-
dance with the following standards: National Fuel Gas Refer to the manufacturers table for line sizing
Code NFPA No. 54, ANSI No. Z223-1.
1. Check suction capacity.
Gas train components upstream of the butter f y valve are
shipped loose. These components should be mounted by 2. Measure total pipe length (horizontal and vertical).
the installer as close to the butterf y valve as practical.
3. Read up from line total feet of copper tube to the
Normally, the control train is ordered to suit a particular intersection line of the specific suction capacity in
code or insurance regulation - such as Underwriters Labo- g.p.h.
ratories / Canadian Underwriters Laboratories (UL / cUL) 4. Read left to column inches of vacuum at fuel unit.
Factory Mutual, or Industrial Risk Insurance. See Figure This is vacuum required to draw oil through pipe listed at
2-4 through 2-6 for component arrangement. Arrange gas given length.
piping at the burner so that the burner is accessible for
servicing without disassembly. 5. Add 1 of vacuum for every foot of lift.

, and is fac- 6. Total inches of vacuum (frictional tube loss plus lift).
The pilot gas train is supplied with the burner
tory installed. The gas pilot supply line must be connected
upstream of the main gas regulator. If a reducing bushing 7. If total exceeds 15, check next larger pipe size.
is required between the house piping and the burner piping, RETURN LINE SIZING. Generally, the return line should
it should be close to the burner shutoff valve. be sized the same as the suction line.
The gas piping must be internally clean and free of for- TWO PIPE - MULTIPLE BURNER SYSTEM. Several
eign material. Before using in service, a leak test must be options exist for a multiple burner installation. In Figure
performed. (SEE SECTION 3-E) 2-10 a typical installation showing separate suction lines
for each burner with a common return line.
F. FUEL OIL PIPING Figure 2-11 shows multiple burners with oil supplied by a
transfer pump. The circulating pump is sized, in this case
PRESSURE ATOMIZATION OIL PIPING for the total suction capacity of all burners. Note that a
The KL and KLG model burners use pressure atomization. special pressure regulating valve is required if the fuel unit
Fuel oil is provided by a burner mounted fuel unit directly inlet pressure is above 3 psi.
coupled to the blower motor via a f exible coupling. The Figure 2-12 shows an installation using a day tank. A pump
suction and return line sizes (two-pipe system) are based supplies oil to the day tank.
on the suction rate of the fuel unit and not the burnerf ring Figure 2-13 shows a f ooded loop system. The circulating
rate. Pipe size must be selected so that suction vacuum pump is sized according to the maximum burnerf ring rate
is within suitable limits. for all burners plus a 30% service factor . The burner return
lines feed into the common supply line.
TWO PIPE - SINGLE BURNER OPERATION. A two-pipe
system is essential. The suction and return between the
storage tank or supply source and the burner must be sized
to supply the required quantity of oil circulated, including NOTE
excess oil returned to the storage tank. INDUSTRIAL COMBUSTION RECOMMENDS THAT
ALL OIL FIRING BURNERS BE EQUIPPED WITHAN
SUCTION LINE SIZING. The Suction load is determined OIL STRAINER (IF NOTINCLUDED WITHTHE BURN-
by: ER) TO PREVENT PARTICLES FROM CLOGGING
THE NOZZLE. IT IS ESSENTIAL TO FOLLOW THE
1. The vertical lift from the oil level in the tank to the STRAINER MANUFACTURERS MAINTENANCE
pump. SCHEDULE TO ENSURE PROPER FIL TRATION.
2. Pressure drop through valves, f ttings, strainers, etc.
3. The friction loss due to oil f ow. This loss varies with:
a. Quantity of oil pumped (gph).

9
 OUTPUT
TO BURNER

SHUTOFF
A
COCK
REGULATOR
MAIN
GAS
VALVE
MAIN
SHUTOFF
GAS
COCK
VALVE

TO
A
BURNER
PILOT
REGULATOR
INPUT
PILOT FROM SUPPLY
VALVE

PILOT
SHUTOFF
COCK
571-0013

FIGURE 2-4
Typical U.L. Gas Train - Low-High-Off System - Size 1 K13 to K25

OUTPUT BUTTERFLY
TO BURNER VALVE

SHUTOFF
A
COCK

MAIN REGULATOR
GAS
VALVE
MAIN
GAS SHUTOFF
VALVE COCK

TO
A
BURNER
PILOT
REGULATOR
INPUT
PILOT FROM SUPPLY
VALVE

PILOT
SHUTOFF
COCK

571-0014

FIGURE 2-5
Typical U.L. Gas Train - Full Modulation System - Size 1 K13 to K25

10
 A

BUTTERFLY HIGH GAS

OUTPUT VALVE PRESSURE
TO BURNER
SWITCH

LOW GAS
PRESSURE
SWITCH
A

SHUTOFF
COCK

A
MAIN
GAS
REGULATOR
VALVE

SHUTOFF
MAIN
COCK
GAS
VALVE

TO
A
BURNER
PILOT
REGULATOR
INPUT
PILOT FROM SUPPLY
VALVE

PILOT
SHUTOFF
COCK

571-0015

Typical U.L. Gas Train - Low-High-Off, Low-High-Low, Size 2 K30 to K42 FIGURE 2-6
Full Modulation System - Size 2-3-4 K30 to K145

NOZZLE
PRESSURE
TAP

N.C.
OIL VALVES FAN HOUSING
BACK CAP

FUEL UNIT
PRESSURE
TAP

MODUTROL
MOTOR

OIL OIL
RETURN NOZZLE

OIL
SUPPLY

FUEL UNIT
571-0004

Low-High-Off, Low-High-Low Oil System, Size 2 - K30 to K42 FIGURE 2-7

11
NOZZLE
PRESSURE
TAP

N.C.
OIL VALVES FAN HOUSING
FUEL UNIT BACK CAP
PRESSURE
TAP

MODUTROL
MOTOR

OIL
NOZZLE

OIL
RETURN

FUEL UNIT

OIL
SUPPLY 571-0005
METERING
VALVE

Full Modulation Oil System Size 1 - K13 to K25 Simplex Nozzle FIGURE 2-8

NOZZLE
PRESSURE
TAP

N.C.
OIL VALVES FAN HOUSING
BACK CAP

CHECK VALVE

MODUTROL
MOTOR

FUEL UNIT
PRESSURE OIL
TAP NOZZLE

OIL
RETURN

FUEL UNIT

OIL
SUPPLY
571-0006
METERING
VALVE

Full Modulation Oil System Size 2, 3, 4 - K30 to K145 Return Flow Nozzle FIGURE 2-9

12
 RETURN TO TANK

OIL
SUPPLY CHECK CHECK
TANK VALVE CHECK VALVE
VALVE
SUPPLY TO BURNERS

BURNER BURNER
NOZZLE NOZZLE
CHECK GATE
VALVE VALVE
GATE
VALVE
GATE
VALVE

GATE
VALVE

OIL RETURN OIL RETURN

OIL INLET OIL OIL INLET OIL

METERING METERING
FUEL VALVE FUEL VALVE
571-0016 FILTER UNIT FILTER UNIT

Multiple Burners with separate suction lines FIGURE 2-10

RETURN TO TANK BACK PRESSURE VALVE
SET BELOW 3 PSI
CHECK
VALVE
GATE CHECK CHECK
VALVE VALVE VALVE

SUPPLY TO BURNERS

CHECK
VALVE BURNER BURNER
NOZZLE NOZZLE
PRESSURE GAUGE
W/ISOLATOR
PRESSURE
GAUGES
W/ISOLATORS GATE
VALVE
VOLUME
CONTROL
BY-PASS
GATE
VALVE
OIL RETURN OIL RETURN

OIL INLET OIL OIL INLET OIL

METERING METERING
FUEL VALVE FUEL VALVE
FILTER UNIT FILTER UNIT

RELIEF
VALVE
VACUUM OR COMPOUND
OIL GAUGE W/ISOLATOR
SUPPLY
TANK GATE GATE
VALVE VALVE CHECK
VALVE

TRANSFER
PUMP
STRAINER
571-0017

Typical Oil Loop for Multiple Burners with Transfer Pump FIGURE 2-11

CHECK BURNER
VALVE NOZZLE

DAY
TANK

GATE
RELIEF VALVE
VALVE
VACUUM OR COMPOUND
OIL GAUGE W/ISOLATOR
SUPPLY OIL RETURN
TANK GATE GATE
VALVE VALVE CHECK OIL INLET OIL
VALVE
METERING
FUEL VALVE
TRANSFER STRAINER UNIT
PUMP
STRAINER
571-0018

Typical Installation Using Day Tank FIGURE 2-12

13
 VACUUM BREAKER

6"
MINIMUM

CHECK BURNER CHECK BURNER

VALVE NOZZLE VALVE NOZZLE
CHECK
VALVE

PRESSURE PRESSURE
GAUGE GAUGE
GATE GATE
VALVE VALVE

OIL RETURN OIL RETURN

OIL INLET OIL OIL INLET OIL

METERING METERING
FUEL VALVE FUEL VALVE
STRAINER UNIT STRAINER UNIT

OIL
SUPPLY GATE STRAINER VACUUM GAUGE
TANK VALVE W/ISOLATOR

VACUUM GAUGE
STRAINER
W/ISOLATOR
GATE GATE
VALVE VALVE
GATE
VALVE
TRANSFER TRANSFER
PUMP PUMP

571-0019 DUPLEX PUMP SYSTEM

Typical Flooded Loop System FIGURE 2-13

G. INSTALLATION CHECKLIST
1. All burners are carefully assembled and tested at the
factory, but before being placed in service all connectors
CAUTION
should again be checked for looseness caused during
BEFORE OPENING THE MANUAL GAS
shipment.
SHUT-OFF VALVES, READ THE REGULA-
TOR INSTRUCTIONS CAREFULL Y. THE
Check:
INSTRUCTIONS ARE IN THE REGULATOR
a. Electrical terminals in the control panel and on all elec-
BOX. FOLLOW THE MANUFACTURER REC-
trical components.
OMMENDATIONS. OPEN SHUT -OFF VALVE
b. Pipe f ttings and unions.
ON THE INLET SIDE OF THE REGULATOR
c. Tubing connections.
SLOWLY AND CAREFULLY TO ALLOW IN-
d. Nuts, bolts, screws.
LET PRESSURE TO BUILDUP SLOWLY IN
THE REGULATOR UNTIL IT IS FULLY PRES-
2. Open all necessary oil shutoff valves. Do not run pumps
SURIZED. OPENING THE SHUT-OFF VALVE
or fuel unit without oil.
QUICKLY WILL DAMAGE THE REGULATOR.
DO NOT EXCEED THE REGU-
3. Before connecting electrical current to any component,
L AT O R P R E S S U R E R A T I N G S .
be sure the voltage is the same as that specif ed on com-
ponent nameplates.

4. Before burner operation, be sure all motors are rotating

in the proper direction.

5. Before f ring, make sure the burner f ring head and

dry areas of the boiler are protected with refractory . The
burner mounting f ange must be properly sealed against
the vessel front plate.

6. Make certain that the operator in charge is properly

instructed in operation and maintenance procedures.

14
 SECTION 3
STARTING UP AND OPERATION
A. PREPARATION FOR INITIAL START-UP
When the installation is complete and all electrical, fuel,
water and vent stack connections are made, make certain
said connections are tight. The operator should become
familiar with the burner , boiler controls and components.
To identify controls and components refer to drawings and
contents of Section 1. Adjustment procedures given in Sec-
tion 4 should be reviewed prior tof ring. The wiring diagram
should also be studied along with the operating sequence
of burner programmer. Check the electrical power supply
for accordance with the nameplate speci f cations for all
motors and controls.
Read and understand starting instructions before at-
tempting to operate the burner. The following checks must
be made:
BOILER.
Check boiler water level. Be sure all boiler valves are
installed correctly and positioned properly. Set the high limit
control slightly above the operating control. Set operating switches, set switch pressure actuating levels and record
control at the desired temperature or pressure.
B. FIRING PREPARATIONS
Check to make certain that all plugs, connections, link-
ages etc., are tight. Prior to initial f ring, oil f ow and pres-
sure should be verif ed.
GAS BURNERS
A representative of the gas utility should turn on the gas.
Determine by a test gauge upstream of the burner regulator
that suff cient 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 start-up it is recommended that the main gas
shutoff cock remain closed until the programmer has cycled
through pre-purge and pilot sequences to determine that
the main gas valve opens. Turn the burner switch OFF
and let programmer f nish its cycle. Check to see that gas
valve closes tightly.
On burners equipped with high and low gas pressure
settings for future service reference.

BURNER. See the burner specif cation nameplate inside the con-
For protection in shipment, the f ame safeguard control trol panel door for minimum and maximum input rate and
chassis is shipped unmounted. Check all screw connec- required manifold pressure.
tions before attaching f ame safeguard chassis to base.
Screw must be secure to assure low resistance connec- When the conditions covered above and in Section 2
tions. The relay chassis is mounted on the subbase with are assured, the burner is ready for f ring. Refer to Letter
a screw which, when tightened, completes the connection E for starting and operating information.
between the subbase and chassis contacts. Press manual
reset button to be sure safety switch contacts are closed. OIL BURNERS
Prior to initial f ring, oil f ow and pressure should be veri-
Check fuses in main panel and in burner control cabinet. f ed. If the burner is a dual fuel model, make certain that
Check wiring to the burner control cabinet for compliance the main gas shut off cock is closed and the fuel selector
with the wiring diagram and local codes.The control cabinet switch set to OIL.
components are 120 volt. If a control transformer is sup-
plied, ensure that the supply voltage matches its primary OIL FLOW.
voltage. If the oil supply tank is below level of oil fuel unit, it is
recommended that the suction line be primed with oil prior
Check motor rotation by momentarily closing the starter to starting the pump to avoid possibility of damage to pump
or relay. Blower rotation is clockwise when viewed from the through operation without lubrication.
drive end. To check for proper pump rotation, momentarily energize
the starter. With rotation verif ed, operate the pump to de-
Check the pilot electrode setting. Refer to theADJUST- termine that oil circulation exists. Observe the oil burner
MENT section. pressure gauge. If no pressure shows after a few moments,
stop the oil pump and re-prime. If the supply tank is lower
Check control linkage for proper movement of the air than the pump, it is possible that the initial priming of the
volume damper and fuel metering components. This can suction line, followed by operation of the pump, will not
be done by loosening the linkage at the actuator lever and establish oil f ow. This might be caused by obstruction in
manipulating by hand. the suction line, excessive lift, inadequate priming, suction
line leaks, etc. Until oilf ow is established, avoid prolonged
Check the air shutter and adjust low f re setting. Refer operation of the pump. If oil f ow is not established after a
to the ADJUSTMENT section. second priming, investigation is required.

15
 A vacuum (or compound pressure-vacuum) gauge
should be installed at the suction port of the pump. It is
advisable that the reading be less than 15 Hg vacuum.
WARNING
Vacuum in excess of this may cause unstable f ring.
READ THE FLAME SAFEGUARD
OIL PRESSURE AND VACUUM. MANUAL AND FULLY UNDERSTAND
If vacuum gauge reads higher than calculated, look for ITS CONTENT BEFORE ATTEMPT-
restriction in the suction line, a closed valve, kinked copper ING T O OPERATE THIS EQUIP-
tubing, plugged f lter, sticking check valve, frozen oil line, MENT.. SERIOUS PERSONAL IN-
undersized oil line, or excessive lift. JURY OR DEA TH MA Y RESUL T.
When there is a positive head of oil at the fuel unit, either
from a gravity or by pump circulation, the pressure must not
exceed 3 psi at the fuel unit suction inlet. Special pressure WARNING
regulating valves are available for suction pressure above
3 psi. The fuel unit discharge pressure should be set at SHOULD A ST ARTING F AILURE
300 psi. OCCUR FOR ANY REASON, COM-
BUSTIBLE FUMES MA Y FILL THE
BURNER SETTINGS COMBUSTION CHAMBER. NEV -
To ensure reliable and safe burner performance, the ER ATTEMPT T O RE-LIGHT THE
location and gap setting of the electrode for direct-spark BURNER UNDER THESE CONDI-
igniters, and the relative positions of the burner nozzle, TIONS WITHOUT FIRST PURGING
diffuser, and air baff e components must be correctly set.
The air damper blades must be adjusted, relative to the
established f ow rates, to provide the correct amount of air C. SEQUENCE OF OPERATION
for complete eff cient combustion. The programming control sequences the operation of
all controls and components through the starting, ignition,
These items are preset at the factory , but must be f ring, and shutdown cycle. The burner and control system
checked prior to placing the burner into initial service, or are in starting condition when: a. The operating and high
after conducting any service work that may have altered limit control (temperature or pressure) are below their cutof
f
their position. setting; b. All power supply switches are closed; c. Power
is present at the control panel.
Refer to Section 4, ADJUSTMENTS, for the instruc- Refer to the manufacturer s literature on programming
tions. controls and burner wiring diagrams for detailed informa-
tion.
COMBUSTION SETTINGS
Fuel and air f ow rates are individually adjusted at low D. ELECTRICAL INTERFERENCE TEST
f re and at high f re to achieve rated heat input, f ring Prior to putting the burner into service, conduct the fol-
rate turndown, optimum ef f ciency, safe operation, and lowing test to ascertain that ignition spark will not cause
the ability to cope with environmental changes (including the f ame relay to pull in.
air temperature, humidity, barometric pressure), and fuel
property changes. Refer to the nameplate inside the control GAS FIRED
panel for minimum and maximum fuel input ratings. Close the pilot and main line manual gas valves. Start
the burner and at time of pilot trial with just the electrical
Refer to Section 4, ADJUSTMENTS, for the instruc- ignition system energized. The f ame relay should not pull
tions. in (i.e. should not be energized).
Upon completion of successful test, proceed with start-up
TEST EQUIPMENT procedures.
The following test equipment should be on site:
1. Combustion analyzer with O2 or CO2 indication. OIL FIRED
2. U-Tube manometer, or pressure gauge, to measure gas Disconnect the electrical power to the burner . Discon-
pressures (Main and Pilot), pressure and vacuum gauge nect the electric oil safety shutoff valve. Reconnect electric
for the oil burners. power. Close the pilot line manual gas valve, if used.
3. Inclined manometer to measure draft pressures. Start burner and at the time of pilot trial, with just the
4. Smoke spot tester for oil burners and CO analyzer for electrical ignition system energized.The f ame relay should
gas f red units. not pull in.
5. Voltmeter / Ammeter Upon completion of successful test, disconnect power
6. Stack Thermometer and Thermocouples. supply. Reconnect oil safety shutof f valve and turn on
manual pilot gas valve. Reconnect power supply and
proceed with start-up procedures.

16
E. START-UP AND OPERATING
GAS BURNERS:
Performing A Gas Valve Leak Test (Bubble Test)
A gas valve leak-test must also be performed on the
automatic safety shutof f valves located in the main gas
train prior to any initial commissioning or subsequent
maintenance of the burner and gas train systems where
automatic valve proving systems interlocked with the main
burner safety control are not provided. This test should
be performed periodically to ensure no leakage of valves
in their closed or de-energized position.
Refer to the diagram below when following this
procedure. The unit should be taken out of service if the
unit fails any of the following tests. Any defective part
must be replaced prior to putting the equipment back into
service.
WARNING
FAILURE TO FOLLOW THIS PROCEDURE MA Y
RESULT IN EXPLOSION, FIRE, PROPER TY
DAMAGE AND PERSONAL INJUR Y. THIS PRO-
CEDURE MUST BE PERFORMED ONL Y BY
AUTHORIZED AND QUALIFED PERSONNEL.
Close (or shut off) manual valve [7] downstream
of the automatic safety shutoff valves, trapping
gas pressure between the safety shutoff valves
and manual valve and causing a f ame failure.
This should close the auxiliary safety shutoff
valve [4] and main gas safety shutoff valve [5]. If
both or either valve fails to close, do not proceed
further until you correct the problem.
17
Release gas pressure at the leak test cock [8B]
between manual valve [7] and main gas safety
shutoff valve [5], then conduct a bubble test for
leak through blocking valve [5]. If no leak, close
the test cock.
Release gas pressure at test cock [8A] and
bubble test for leak through auxiliary safety
shutoff valve [4]. If you do not observe a leak,
close test cock and go to next step. If either
valve leaks, correct the problem and retest 10
times before proceeding.
When there are no valve leaks, open manual
valve [7] and relight the burners. Then close
manual valve [1]. The safety shutoff and blocking
valve should close due to low gas pressure.
Relight the burners. Reduce the high gas
pressure switch [6] setpoint setting until it
reaches the operating gas pressure, which
should cause the auxiliary and main gas safety
shutoff valves to close from high gas pressure.
Return the setpoint to its original position before
proceeding.
Shut off the combustion air blower. This should
cause a failure due to low air pressure and
cause the safety valves to close.
Reset all manual valves to their normal setting
for operation. Make sure all electric valves are
operating normally. Make sure all test cocks are
closed before resuming normal operation.
 Close the downstream main and pilot gas cocks. Make Do not disturb established lowf re adjustment. Allow the
sure the ON-OFF switch is in the OFF position.Actuate burner to return to lowf re position before adjusting high or
the manual reset button of the f ame safeguard control to intermediate settings. CO levels should be less than 400
close the safety switch contacts. ppm on an air-free basis at all f ring rates, with <50 ppm
as the target value.
For LOW -HIGH-OFF or LOW -HIGH-LOW and FULL
MODULATION models set the MANUAL-AUT O switch When conditions covered above are assured, refer to
to the MANUAL position. Sections F and G of this chapter.
Set the manual potentiometer to low f re position.
OIL BURNERS
Open the gas pilot cock. check pressure. Normal setting The fuel selector switch should be set to OIL and the
is 3 to 6 WC when the pilot is burning. ON-OFF switch is in the OFF position. Actuate the
manual reset button of thef ame safeguard control to close
Set the ON-OFF switch to ON. The burner will start the safety switch contacts.
and pre-purge. After pre-purge, the ignition transformer
and the gas pilot solenoid are energized. Set the ON-OFF switch to ON. The burner will start
and pre-purge. After pre-purge, the ignition transformer will
On initial start-up it is recommended that the main gas direct spark. If the f ame detector proves the presence of
shutoff cock remain closed until the programmer has cycled a satisfactory pilot, the programmer will proceed to main
through prepurge and pilot sequence. Then determine that f ame ignition.
main gas valve opens. When this is con f rmed, turn the
burner switch OFF and let programmer f nish its cycle. Make initial air shutter settings for smooth ignition. Re-
Check to see that gas valve has closed tightly. turn line oil pressure should be set according to Section
If ignition does not occur, turn the burner switch OFF and 4, ADJUSTMENTS. Do not repeat unsuccessful light of f
allow programmer to recycle for a new ignition trial. attempts without rechecking burner and pilot adjustment.
Vent fuel vapors from the combustion chamber after each
Turn burner ON and after pilot ignition when the f ame unsuccessful light off attempt. Set the oil low f re rate by
relay pulls in, the slow opening, motorized, main gas valve adjusting the oil return pressure and air linkage. Refer to
is energized. Slowly open the downstream manual shutof f the adjustment section of this manual. Using combustion
gas cock. Main f ame should ignite at this time. The gas analysis instrument adjust the lowf re. Typical combustion
valve and air damper continue advancing until high f re is analysis for low-f re is 4 to 5% O2.
reached.
When low f re is adjusted, shut down burner . Restart
Do not repeat unsuccessful light of f attempts without several times to be sure the low f re setting is suitable.
rechecking burner and pilot adjustment. Vent fuel vapors Readjust if necessary . Never start the burner with
from the combustion chamber after each unsuccessful light fuel vapor in the furnace. In case of emergency , open
off attempt. Set the gas low f re rate by adjusting butterf y main power switches and close all fuel valves. After
valve and air linkage. Refer to the adjustment section of combustion adjustments are satisfactorily set, allow the
this manual. Using combustion analysis instrument adjust heating vessel to slowly reach normal operating pressure
the low-f re. Typical combustion analysis for low-f re is 4 to or temperature.
5% O2 on standard turndown systems. erify V the minimum
input rate by measuring the gas meter. After the boiler has reached operating temperature
or pressure, turn the potentiometer switch in small
When low f re is adjusted, shut down burner. Restart sever- increments to the high f re position. This will cause the
al times to be sure the lowf re setting is suitable. Readjust metering valve to close, resulting in an increase in the
if necessary. Never start the burner with fuel vapor in the oil pressure feeding the burner nozzle. In high f re the oil
furnace. In case of emergency, open main power switches metering valve should be in the fully closed position and
and close all fuel valves. After combustion adjustments are the fuel oil pressure should be about 300 psi. Check high
satisfactorily set, allow the heating vessel to slowly reach f re at this point using combustion instruments. High f re
normal operating pressure or temperature. combustion analysis typically is 3 to 4.0% percent O2.
Verify maximum input rate by measuring the oil meter if
After the boiler has reached operating temperature or pres- available or by weighing the oil.
sure, turn the potentiometer switch in small increments to
the high f re position. Check high f re at this point using The burner should be set-up and maintained to yield
combustion instruments. High f re combustion analysis smoke spot levels less than a #1 spot (ASTM D2156
typically is 2 to 3.5 percent O2. Verify maximum input rate Shell-Bacharach Scale) to minimize soot build-up in the
by measuring the gas meter. boiler.

18
Do not disturb established low f re adjustment. Allow the
burner to return to low f re position before adjusting high
or intermediate settings.
When conditions covered above are assured, refer to
letters F and G of this section.
COMBINATION GAS-OIL BURNERS
In general, the combination fueled system is to be
started f rst using oil, because, as a fuel, oil has a greater
combustion air requirement than natural gas.
Refer to the Gas burner or Oil burner adjustment
procedures and to Section 4, ADJUSTMENTS.
Once the adjustments are set for oil, shut-down the
burner and re-start and adjust the natural gas fuel. DO
NOT READJUST THE AIR SHUTTERS. The adjustment
is made by balancing the fuel input rate against the
existing f ow of combustion air.
When conditions covered above are assured, refer to
letters F and G of this section.
NOTE
SIZE 1 & 2 COMBINA TION GAS/OIL UNITS
USE A DIRECT COUPLING FROM THE
BLOWER MOTOR TO THE OIL PUMP. WHEN
FIRING GAS FOR AN EXTENDED PERIOD
OF TIME, THE COUPLING SHOULD BE
MANUALLY REMOVED AND REPLACED
ONLY WHEN FIRING OIL. IF THE COUPLING
IS LEFT CONNECTED TO THE BLOWER
MOTOR, ENSURE THAT THERE IS PROPER
OIL CIRCULATION AT ALL TIMES TO AVOID
DAMAGE AND SEIZURE OF THE PUMP.
ACCESS
COVER
BLOWER
MOTOR
IMPELLER
FLEXIBLE
571-0020
COUPLING
Figure 3-1
19
F. NORMAL OPERATION
Normal operation must be with the MANUAL-AUT O
switch selector at AUTO.
In automatic operation, the operating cycle always pro-
ceeds sequentially through pre-purge, pilot ignition, main
f ame ignition, run and post-purge. The length of purge
and ignition trial vary according to the type of programmer
used.
During the run cycle, burner input is regulated to the load
demand by the modulating pressure or temperature control
on the boiler. The burner will continue to modulate until
the operating pressure or temperature is reached.
Programmer control operation should be tested when
the burner is initially placed into service, when a control is
replaced, and at scheduled intervals in the maintenance
program.
Refer to adjustments procedures and maintenance in-
structions given in Sections 4 and 5.
G. SHUTDOWN
When the operating limit control setting is reached or
the burner switch is turned OFF, the following sequence
occurs:
The fuel valve(s) de-energize and f ame extinguishes.
The blower motor continues running during post-purge (if
so equipped with post-purge feature).
At the end of the post-purge the blower motor is de-
energized. The programmer returns to its starting position
and stops. Unit is ready to restart.
Abnormal shutdown might result from motor overload,
f ame outage, low water, current or fuel supply interruption,
combustion or atomizing air pressure below minimum level,
tripped circuit breakers, blown fuses, or other interlock
devices. Check for cause and correct before restarting
burner.
Safety shutdown caused by ignition or f ame failure will
actuate a red indicator light and energize an audible alarm
(if so equipped). If the programmer has a non-recycling
interlock circuit, any interruption in this circuit during the
pre-purge or f ring cycle will cause a safety shutdown.This
type of shutdown requires manual reset of the program-
ming control and must be corrected before operation can
be resumed.
 SECTION 4
ADJUSTMENTS
A. GENERAL
While each burner is tested at the factory for correct 1. Combustion analyzer for O2 or CO2 indicator.
operation before shipment, variable conditions such as 2. U-Tube manometer, or pressure gauge, to measure
burning characteristics of the fuel used and operating load gas pressures (Main and Pilot), Vacuum and pres-
conditions may require further adjustment after installation sure gauges for oil.
to assure maximum operating eff ciency. 3. Inclined manometer to measure draft pressures.
Prior to placing the boiler into initial service, a complete 4. Smoke spot tester for oil burners and CO analyzer
inspection should be made of all controls, connecting for gas f red units.
piping, wiring, and all fastenings such as nuts, bolts and 5. Voltmeter / Ammeter
setscrews to be sure that no damage or misadjustments 6. Stack Thermometer and Thermocouples.
occurred during shipment and installation.
A combustion eff ciency analysis made during the initial AIR FLOW ADJUSTMENTS
start-up will help to determine what additional adjustments The K/Series burners have a unique air shutter
are required in a particular installation. design that enables precise, independent air f ow rate
adjustments for both the high-f re and low-f re operating
B. COMBUSTION ADJUSTMENT ON OIL points. This design incorporates a variable main air
AND GAS shutter (mounted on a shaft and direct-coupled to
Ef f cient combustion cannot be properly judged byf ame the modulating motor), plus two adjustable, but non-
appearance, although it may help in making preliminary modulating, air shutters.
settings.
The proper settings of air-fuel ratios must be determined
by f ue gas analysis. Combustion gas analysis indicates
NOTE
the air to fuel ratio and the degree of complete combus- THE LOW -HIGH-OFF, LOW -HIGH-LOW
tion. Instruments are available to measure carbon dioxide BURNERS ARE EQUIPPED WITH A SINGLE
(CO2), oxygen (02), and carbon monoxide (CO). At no AIR DAMPER BLADE. THE SPECIAL AIR
time should CO2 measurements alone be used to indi- SHUTTER DESIGN IS APPLICABLE ONLY
cate proper excess air levels. Only O2 measurement can FOR THE FULL MODULATION SYSTEMS.
def nitively show whether suff cient air has been provided
for combustion. The modulating main air shutter regulates the f ow of
inlet air through the fan at f ow rates between high- f re
STACK TEMPERATURE and low-f re conditions according to the modulating motor
Net stack temperature is obtained by subtracting the position. One non-modulating air shutter , for high- f re
ambient temperature from thef ue gas temperature. A high combustion air control, is adjusted to provide the correct
net stack temperature indicates wasted heat. Decreasing amount of air while the system is operating at high- f re fuel
either the temperature or the volume of the f ue gas, or input rate with the main air shutter fully open. The other
both can reduce stack heat loss. Flue gas temperature is non-modulating shutter, for low-f re combustion air control,
reduced by improving heat transfer or by reducing excess is adjusted to provide the correct amount of air with the
combustion air. A certain amount of excess air is necessary system operating at low-f re input rate with the main shutter
to complete combustion. More ef f cient burners require completely closed.
minimum excess air.
The three air shutters are mounted inside the air box
SMOKE MEASUREMENT assembly. The high-f re and low-f re shutters are mounted
Smoke measurements can be made using a variety on independent shafts. A pointer, mounted on each shaft,
of different methods. The standards will vary somewhat indicates the set position of each non-modulating shutter.
according to the equipment used, and instructions accom- Adjustment of these shutters is accomplished by loosening
panying the instrument should be followed. a setscrew that holds the shutter shaft within a stationary
Smoky combustion can result from: Improper air delivery , collar mounted on the air box.
insuff cient draft, improper fuel viscosity, improper fuel-air
ratio, excessive air leaks in the combustion chamber , or COMBUSTION SETTINGS
improper fuel oil temperature. Fuel and air f ow rates are individually adjusted at low-
f re and at high- f re to achieve rated input, f ring rate
TEST EQUIPMENT turndown, optimum ef f ciency, safe operation, and the
The following test equipment should be used to set-up ability to cope with environmental changes (including air
and adjust the burner correctly: temperature, humidity , barometric pressure), and fuel

20
property changes.
Turndown capability for oil is less than that for gas due
to the excess air requirement of oil for clean combustion.
Therefore, on combination fueled burners, gas turndown
performance may be restricted (or determined) by the
excess air levels set initially for oil combustion.
Two key components residing in f ue gas are used to
optimize combustion eff ciency; excess air and unburned
fuel. The system should be adjusted to the minimum
excess air quantity that provides low levels of unburned
fuel with suff cient remaining oxygen to cope with normal
atmospheric and fuel related changes. Unburned fuel
is measured as carbon monoxide (CO) when burning
natural gas, and smoke spots when burning oil.
GAS ADJUSTMENTS
Low- f re combustion analysis typically is 7 to 9 percent
CO2 and less than .04 percent CO (400 ppm). High- f re
reading typically is 9 to 10.5 percent O2 and less than .04
percent CO. The K/Series burners are capable of operat-
ing at low excess air and less than 50 ppm CO levels at
all f ring rates.
FUEL OIL ADJUSTMENTS
Adjust for a clean f re. Typically for No. 2 oil, CO2 is 8
to 11 percent at low-f re and 10 to 13 percent at high-f re.
The burner should be set-up and maintained to yield
smoke spot levels less than a #1 spot (ASTM D2156 Shell-
Bacharach Scale) to minimize soot build-up in the boiler.
C. GAS PILOT FLAME ADJUSTMENT
Burner models KG-KLG and KL-54 to 145 are equipped
with a gas pilot system.The gas pilot f ame is regulated by
adjusting the pressure setting of the pilot regulator
. Normal
setting is 3 to 6 WC when the pilot is burning. The f ame
must be suff cient to be proven by the f ame detector and
D. DIRECT SPARK OIL PILOT ADJUSTMENT
Burner models KL-13 to 42 are equipped with a direct
spark ignition. Remove the oil drawer assembly and check
electrode settings and nozzle size.
E. BURNER SETTINGS
To ensure reliable and safe burner performance, the
location and gap setting of the electrodes, and the rela-
tive positions of the burner nozzle, dif fuser and air baf f e
components must be set correctly. These items are preset
at the factory , but must be checked prior to placing the
burner into initial service, or after conducting any service
work that may have altered their position.
The nozzle/dif fuser assembly must be removed
from inside the burner to enable measurement and
adjustment.
Remove as follow:
1. Lock out and tag the electrical power supply to the
burner to prevent inadvertent operation during check-
out or maintenance activities.
2. Disconnect the high voltage power supply from the oil-
spark-ignition electrodes (if installed).
3. Disconnect the f ame scanner and oil piping from the
end of the blast tube.
4. Remove the fasteners that secure the drawer to the
side of the fan housing, and remove the complete
assembly.
5. For burners with a gas pilot: Disconnect the pilot line
and loosen the locking screws on the pilot access
cover located on the side of the blast tube. Disconnect the
high voltage ignition cable by pulling it straight back, away
from the pilot assembly. The pilot assembly will slide back
CENTER
ELECTRODE

ignite the main f ame. Although it is possible to visibly ad-

IN OPENING

just the size of the pilot f ame, obtain a proper DC volt or

microamp reading of the f ame signal.
The f ame safeguard amplif er has a meter jack for this
purpose. At initial start-up and during planned maintenance, ELECTRODE
FLUSH W/END

test the pilotf ame signal, pilot turndown, and safety switch OF TUBE

lockout. Refer to the f ame safeguard instruction manual. 8-3/4"

571-0025

Size 1 & 2 Gas Pilot

WARNING
AN UL TRA-VIOLET FLAME SENSOR ELECTRI- SET ELECTRODE
TIP AT THE

CAL SP ARK INTERFERENCE TEST MUST BE 9:00 O'CLOCK

POSITION

PERFORMED AFTER FINAL ADJUSTMENT. SEE

SECTION 3 OF THIS MANUAL FOR ADDITIONAL
INFORMATION.
ELECTRODE END
WITHIN 1/4"

Check the pilot electrode setting. The pilot is accessible

FROM TUBE END TIP TO TUBE
GAP OF 1/32"

by loosening the four screws on the side of the blast tube 9-5/16" 571-0026

and disconnecting the gas line. Size 3 & 4 Gas Pilot

Figure 4-1

21
and away from the diffuser. Turn the assembly and retract
it through the access hole. Check the electrode position as
illustrated in Figure 4-1. Reassemble in reverse order.

Measure the position and gap of the pilot electrodes

and compare to the dimensions in Figure 4-2. Adjust as
follows:

1/8" BETWEEN
INNER EDGES OF
THE ELECTRODES
7/16" FROM
CENTER OF NOZZLE
TIPS TO BOTTOM
EDGE OF THE Figure 4-3
ELECTRODES Size 1, KL & KLG-13 to 25
1/4" FROM
NOZZLE TIPS TO
OUTER EDGE OF
571-0027 THE ELECTRODES

Direct spark ignition Figure 4-2

1. Loosen the locking screws on the spark ignition clamp

assembly.
2. Rotate and slide each electrode in the clamp, as neces-
sary, to achieve the correct position relative to the burner
tip.
3. Tighten the locking screws securely to lock the electrode
in position. Apply a lock-tight type compound to the screws Figure 4-4
Size 2, KL & KLG-30 to 42
before tightening.
Measure the position of the tip of the nozzle to thefuser
dif
and compare to the following drawer assembly drawings.
Adjust as follows:
1.Loosen the locking screws on the diffuser clamp.
2.Slide the dif fuser clamp along the length of the burner
pipe until the correct dimension is achieved.
3. Tighten the diffuser clamp securely to the burner pipe.
Apply a lock-tight type compound to the screws before
tightening.
4. Carefully install the drawer assembly into the burner .
Reconnect the oil line, scanner , and high voltage power
cable to the assembly. Figure 4-5
Size 3, KL & KLG-54 to 84
Measure the position of the dif fuser to air baf f e and
compare to the following drawer assembly drawings. Adjust
as follows:
1. Measure the distance between the leading edge of the
diffuser and the front face of the inner ring on the air baf
fe
assembly.
2. If adjustment is required, loosen the burner pipe locking
setscrew located on the rear cap at the top of the fan
housing, and slide the burner pipe until the correct
dimension is achieved.
3. Tighten the burner pipe locking setscrew securely.
Figure 4-6
Size 4, KL & KLG-105 to 145
NOTE
Maximum valve inlet pressure for the V4944 is 0.5
PSI. If line pressure is greater, an over pressure
device is to be installed down stream of main gas
regulator. (CSD-1-CF160)

22
F. PILOT TURN DOWN TEST valve is used. This valve uses two pressure regulators
For burners equipped with a gas pilot, conduct the follow- (low-f re and high- f re) and two solenoids to provide two
ing test: distinct stages of pressure regulation. High- f re is obtained
1. Turn the burner switch on.This will start the blower motor when the 2nd style solenoid is energized by the auxiliary
and initiate the prepurge sequence. Make sure a pres- switch in the M346 Mod Motor.
sure gauge 0-10 w.c. or manometer is installed in the 1. Open the manual gas shut-off cocks.
pilot line to monitor the pilot gas pressure. 2. Check the gas pressure at the inlet of the regulator and
2. When the pilot comes on, put the programmer timer on the pressure downstream of the regulator. Make sure
pilot hold by placing the Run-Test switch of the f ame they are in accordance with the regulator specif cations.
safeguard to the Test position. The gas pressure required at the manifold is the pressure
that is required to f re the burner at its rated capacity. To
Refer to the flame safeguard control manual instruc- adjust the regulator, unscrew the cap located on top and
tions. turn the adjustment screw clockwise to increase pressure,
or counter-clockwise to decrease pressure.
3. Check thef ame signal strength.Adjust the f ame signal 3. Turn the burner switch to the ON position.
by increasing or decreasing pilot gas pressure with the 4. Set the thermostat or control to energize the V4944 valve
regulator spring. Normal setting is 3 w.c. to 4 w.c. and check f nal outlet pressure. Allow enough time for the
4. Perform a pilot turndown test by reducing the pilot pres- pressure to stabalize (valve outlet pressure measurements
sure very slowly until the scanner looses sight of the are made at a point approximately f ve pipe diameter
f ame and give a f ame lock-out, than reset the adjust downstream from the valve outlet). Low- f re outlet range
ment to normal level. Note the minimum pressure level. is 0.85 wc to 2.0 wc for natural gas and high- f re outlet
5. After adjusting the pressure back to normal level, set the range is 3 wc to 4.5 wc.
programmer to the Run position. Main f ame will come 5. To adjust the pressure, temporarily remove the slotted
on and the burner is in the low f re position. aluminum screw cap and gasket from the housing that
6. Start and stop the burner several times to ensure proper contains the regulator adjustment setscrew. Turn the ad-
pilot setting. justment setscrew clockwise to increase the pressure or
counterclockwise to decrease the pressure setting. Allow
G. LOW-HIGH-OFF & LOW-HIGH-LOW enough time for the pressure to reach equilibrium between
pressure adjustment.
BURNER ADJUSTMENTS 6. After a few seconds, the O 2 analyzer should have an
Refer to the burner data plate located inside the control accurate reading of the O2 present in thef ue gas. Normally,
panel door. The nameplate will list the burner information: O 2
levels are set between 4 to 6 percent at low- f re, with
Burner and control voltage, phase, cycle, motor amperage, less than 50 ppm CO.To obtain the proper readings, adjust
maximum and minimum fuel input settings, manifold pres- the air shutter and low-f re regulator pressure.
sure (at zero furnace pressure. Add the furnace pressure 7. Operate the boiler at low-f re until it is up to operating
to get the correct manifold pressure at maximum f ring pressure (steam) or temperature (hot water).
rate). 8. Bring the burner to the high-f re position and adjust the
These procedures assume that the pre-start-up tasks, regulator pressure. Adjust the high-f re gas input to match
check list, electrical interference test, and pilot turn-down maximum rating. Adjust the gas regulator so the manifold
tests, have been performed in accordance with the instruc- pressure matches the rating on the burner data plate.
tions in this manual. Verify and record your readings and pressures. High- f re
Allow boiler to fully warm up before making adjustments is typically 2 to 4% O 2
with less than 50 ppm CO.
for most eff cient combustion. Refer to the boiler instruction
manual for the boiler controls settings. The burner should be adjusted to provide correct fuel
f ow at a constant rate, at the lowf re and high f re position
GAS BURNERS as indicated on the burner data plate. This is achieved by
The gas burner adjustments on a Low-High-Off system clocking the gasf ow at the gas meter.The gas utility or gas
consist of the gas pressure regulator, butterf y gas valve, meter calibration data, should be consulted to determine
low and high gas pressure switches, and air damper. the correction factors to be applied to the meter.
The auxiliary switch inside the M436 Mod motor
makes or breaks the high- f re gas. See Fig.10 for switch Use the following formula to determine actual f ow:
adjustment. The Low-High-Low boiler control energizes Gas Input
BTU
= HHV x
Patm+ Pgas
x 520 x 3600 s x RATE ft
3

the M436 motor , driving it to high- f re. When the boiler hr 29.92 Tgas + 460 hr s
control denergize the M436, a built in return spring drives
it to the low-f re position. Where:
HHV = The higher heating value of the gas in Btu/ft3
The Size 1, KG-13 to 25, use a Honeywell V4944 two- (contact your local gas company for an exact measure-
stage solenoid operated diaphragm valve. No butter f y ment).

23
Patm = Atmospheric pressure in inches of mercury. sure adjustment is 100-200 PSI (solenoid de-energized).
High-f re pressure adjustment is 200-300 PSI (solenoid
Pgas = Gas pressure ahead of the volumetric f ow meter energized).
in inches of mercury. 1. Turn the burner switch to the ON position.
2. Adjust low f re with the oil pressure regulating valve to
Tgas = Gas temperature at the volumetric f ow meter in have approximatly 100 to 200 PSI, and adjust the air
Deg.F shutter for a clean f re. Record your combustion reading
from the f ue gas analyzer , normally 8 to 1 1 percent O 2
RATE = Natural gas rate taken with the volumetric f ow and less than No.2 Smoke (Bacharach). To adjust the oil
meter in ft3 /second pressure regulating valve, remove lockscrew and adjust
pressure by turning the allen screw clockwise to increase
9. After completing all adjustments, replace the regulators pressure, and counterclockwise to reduce pressure.
gaskets and slotted aluminum screw caps.Tighten all link- 3. Operate the boiler at low-f re until it is up to operating
ages and marked settings. Complete the Start-Up report pressure (steam) or temperature (hot water).
at the end of this section. 4. Adjust the high-f re fuel input to match maximum oil
pressure. At high-f re, the pressure should be 300 PSI.
The size 2, KG-30 to 42, use a butter f y gas valve to control Verify and record your readings and pressures. High-f re
the gas f ow to the burner. The M436 Mod motor controls is typically 11 to 13% CO2 with less than No.2 smoke.
the position of the valve. The burner should be adjusted to provide correct fuel
1. Open the manual gas shut-off cocks. f ow at a constant rate, at the low-fre and high-f re position
2. Check the gas pressure at the inlet of the regulator and as indicated on the burner data plate.
the pressure downstream of the regulator . Make sure 5.Tighten all linkages and marked settings. Complete the
they are in accordance with the regulator speci f cations. Start-up report at the end of this section.
The gas pressure required at the manifold is the pressure
that is required to f re the burner at its rated capacity. To COMBINATION GAS-OIL BURNERS
adjust the regulator, unscrew the cap located on top and In general, the combination fueled system is to be started
turn the adjustment screw clockwise to increase pressure, f rst using oil, because as a fuel, oil has a greater combustion
or counterclockwise to decrease pressure. air requirement than natural gas. After being completely
3. Turn the burner switch to the ON position. adjusted for oil combustion, the burner is re-started and
4. The burner will start and be in the low-f re position. adjusted using natural gas as fuel. Combustion adjustment
5. After a few seconds, the O 2 analyzer should have an of the combination burner for natural gas involves balancing
accurate reading of the O 2 present in the f ue gas. Nor- the input rate only against the existing f ow of combustion
mally, O2 levels are set between 4 to 6 percent at low-f re, air, as established initially for oil.
with less than 50 ppm CO. To obtain the proper readings, Do not readjust the air shutter when tuning the combi-
adjust the gas butterf y opening and air shutter. Take note nation burner for combustion of natural gas.
of the readings and pressures at the burner manifold and 1. Turn the fuel selector switch to the OIL position.
gas train. 2. Turn the burner switch to the ON position.
6. Operate the boiler at low- f re until it is up to operating 3. Proceed with start-up and adjustments using the same
pressure (steam) or temperature (hot water). procedures def ned in the Oil Burners section.
7. Bring the burner to high-f re position. Adjust the high-f re 4. After the system has been completely adjusted for oil
gas input to match maximum rating. At high-f re, the but- f ring, place the burner switch OFF, and position the fuel
terf y valve should be near the full open position. Adjust the selector switch to GAS.
gas regulator so the manifold pressure matches the rating 5. Proceed with start-up and adjustments using the same
on the burner data plate. Verify and record your readings procedures def ned in the Gas Burners section. Do not
and pressures. High-f re is typically 2 to 4% O 2 with less alter the air settings set for oil. Correct your O2 levels by
than 50 ppm CO. adjusting the butterf y valve for Size 2 models, and the
8. Adjust the low and high gas pressure switches by turn- regulators low and high pressures for Size 1 models.
ing the adjusting screw until indicator moves to a pressure
slightly lower than normal operating pressure for the low H. FULL MODULATION BURNER
gas pressure switch, and slightly higher for the high gas ADJUSTMENTS
pressure switch (usually 20% below and 20% higher than Refer to the burner data plate located inside the control
normal pressure). panel door. The nameplate will list the burner information:
9. Verify low-f re and high- f re rate by clocking the meter Burner and control voltage, phase, cycle, motor amperage,
as previously explained. maximum and minimum fuel input settings, and manifold
pressure (at zero furnace pressure. Add the furnace pres-
OIL BURNERS sure to get the correct manifold pressure at maximum f ring
The Suntec B2TD-8842 oil pump is typically incorporated rate.).
and is a two-stage, two step oil pump. The low-f re pres- These procedures assume that the pre-start-up tasks,

24
check list, electrical interference test, and pilot turn-down
tests, have been performed in accordance with the instruc-
tions in this manual.
Allow boiler to fully warm up before making adjustments
for most eff cient combustion. Refer to the boiler instruction
manual for the boiler controls settings.
GAS BURNERS
The gas burners adjustments on a full modulation burner
consist of the gas pressure regulator, butterf y gas valve,
low and high gas pressure switches, and air dampers.
1. Open the manual gas shut-off cocks.
2. Check the gas pressure at the inlet of the regulator and
the pressure downstream of the regulator. Make sure
they are in accordance with the regulator specif cations.
The gas pressure required at the manifold is the pressure
that is required to f re the burner at its rated capacity. To
adjust the regulator, unscrew the cap located on top and
turn the adjustment screw clockwise to increase pres-
sure, or counter-clockwise to decrease pressure.
3. Set the Manual-Auto switch on the Manual position.
4. Position the manual f ame control potentiometer in the
CLOSED (Low-Fire) position.
5. Turn the burner switch to the ON position.
6. The burner will start and be in the low-f re position.
7. After a few seconds, the O2 analyzer should have an ac-
curate reading of the O2 present in the f ue gas. Normally,
O2 levels are set between 4 and 6 percent at low-f re, with
less than 50 ppm CO.To obtain the proper readings, adjust
the gas butterf y opening and low-f re air shutter. Take note
of the readings and pressures at the burner manifold and
gas train.
8. Operate the boiler at low-f re until it is up to operating
pressure (steam) or temperature (hot water). Then in-
crease the fuel input to the boiler by turning the manual
f ame control potentiometer towards OPEN in small
increments. This will cause the butterf y valve to open,
allowing more gas into the burner.
9. At each point, allow the burner to operate for a few
minutes before recording your O2, CO and pressure
readings. Observe that your O2 and CO levels remain
within an acceptable limit. Adjust the pressure regulator,
as necessary, to correct this situation. For burners with
the cam trim option, adjust the cam screws throughout the
range to obtain correct O2 and CO levels. Continue to
do this until the burner reaches high f re (the potentio-
meter is at the OPEN position).
10. Adjust the high-f re gas input to match maximum rating.
At high-f re, the butterf y valve should be near the full
open position. Adjust the gas regulator so the manifold
pressure matches the rating on the burner data plate.
Verify and record your readings and pressures. High-f re
is typically 2 to 4% O 2 with less than 50 ppm CO as a
target value. Adjust the high-f re excess air rate using the
high-f re shutter adjustment.
11. Modulate the burner to low- f re. Verify the readings
once again.
The burner should be adjusted to provide correct fuel
25
f ow at a constant rate, at the low-fre and high-f re position
as indicated on the burner data plate. This is achieved by
clocking the gasf ow at the gas meter.The gas utility or gas
meter calibration data, should be consulted to determine
the correction factors to be applied to the meter
Use the following formula to determine actual f ow:
BTU Patm+ Pgas 520 x 3600 s x RATE ft
3
Gas Input = HHV x x
hr 29.92 Tgas + 460 hr s
Where:
HHV = The higher heating value of the gas in Btu/ft3
(contact your local gas company for an exact measure-
ment).
Patm = Atmospheric pressure in inches of mercury.
Pgas = Gas pressure ahead of the volumetric f ow meter
in inches of mercury.
Tgas = Gas temperature at the volumetric f ow meter in
Deg.F
RATE = Natural gas rate taken with the volumetric f ow
meter in ft3 /second
12.Adjust the low and high gas pressure switches by
turning the adjusting screw until indicator moves to a
pressure slightly lower than normal operating pressure
for the low gas pressure switch, and slightly higher for the
high gas pressure switch (usually 20% below and 20%
higher than normal pressure).
13.Tighten all linkages and marked settings. Complete the
Start-up report at the end of this section.
14.Turn the Manual-Auto switch to AUTO. The burner
will now modulate according to the load demand to the
boiler.
OIL BURNERS
The oil burner adjustments consist of the oil metering valve
and air shutters. The f ring rate is regulated by a metering
valve in the nozzle return line.At low-f re, the arrow on the
valve points to approximately number 7, and at high-f re it
is in the closed position (no return f ow), approximately at
number 2.The oil metering valve position will vary the oil
pressure to the nozzle. An oil pressure gauge should be
installed in the return line to monitor the oil pressure. Oil
pressure at low-f re is approximately 80 to 100 PSI and 300
PSI at high-f re. Size 1, 2 and 3 K burners use a simplex
nozzle. Size 4 K burners use a return f ow nozzle.
1. Set the Manual-Auto switch on the Manual position
2. Position the manual f ame control potentiometer in the
CLOSED (Low-Fire) position.
3. Turn the burner switch to the ON position.
4. The burner will start and be in the low-f re position.
5. Adjust low-f re with the metering valve position to have
approximately 80 to 90 PSI, and adjust the low- f re air
shutter for a clean f re. Record your combustion reading
from the f ue gas analyzer, normally 8 to 1 1 percent CO 2 alter the air settings set for oil. Correct your O2 levels by
and less than No.2 Smoke (Bacharach). adjusting the butterf y valve.
6. Operate the boiler at low- f re until it is up to operating
pressure (steam) or temperature (hot water). Then increase
the fuel input to the boiler by turning the manual f ame control
potentiometer towards OPEN in small increments.This will
cause the metering valve to close, resulting in an increase
in the oil pressure feeding the burner nozzle.
7. At each point, allow the burner to operate for a few min-
utes before recording your CO2, CO, Smoke and pressure
readings. Observe that your CO 2 and CO levels remain
within an acceptable limit. Adjust the oil pressure as nec-
essary, to correct this situation. For burners with the cam LOW FIRE
MAIN AIR
trim option, adjust the cam screws throughout the range AIR SHUTTER
SHUTTER

to obtain correct CO 2 and CO levels. Continue to do this (W/INDICATOR)

(SHOWN IN LOW
until the burner reaches high- f re (the potentiometer is at FIRE POSTION)
HIGH FIRE
the OPEN position).
8. Adjust the high- f re fuel input to match maximum oil
pressure. At high-f re, the metering valve should be in the
fully closed position and the pressure should be 300 PSI.
Verify and record your readings and pressures. High- f re
is typically 11 to 13% CO2 with less than No.2 smoke. Ad-
just the high-f re excess air rate using the high-f re shutter
adjustment. HIGH FIRE
9. Modulate the burner to low- f re. Verify the readings once AIR SHUTTER
again. The burner should be adjusted to provide correct fuel 571-0023 (W/INDICATOR)
f ow at a constant rate, at the lowf re and high f re position FIGURE 4-7
as indicated on the burner data plate. TYPICAL LOCATION OF
10. Tighten all linkages and marked settings. Complete the THE POINTER WHEN AT
Start-up report at the end of this section. 8 10 1
HIGH FIRE 2
11. Turn the Manual-Auto switch to AUTO. The burner 6
will now modulate according to the load demand to the

14
4
boiler.

16
2

COMBINATION GAS-OIL BURNERS

18
In general, the combination fueled system is to be started
0

CLOSED OPEN

f rst using oil, because as a fuel, oil has a greater combus-

tion air requirement than natural gas. After being completely
adjusted for oil combustion, the burner is re-started and
adjusted using natural gas as fuel. Combustion adjustment
of the combination burner for natural gas involves balancing
the input rate only against the existing f ow of combustion 571-0022
air, as established initially for oil.
Do not readjust the air shutters when tuning the com- FIGURE 4-8
bination burner for combustion of natural gas.

1. Set the Manual-Auto switch on the Manual position.

2. Position the manual f ame control potentiometer in the
CLOSED (Low-Fire) position.
3. Turn the fuel selector switch to the OIL position.
4. Turn the burner switch to the ON position.
5. Proceed with start-up and adjustments using the same
procedures def ned in the Oil Burners section.
6. After the system has been completely adjusted for oil
f ring, place the burner switch OFF, and position the fuel
selector switch to GAS.
7.Proceed with start-up and adjustments using the same
procedures def ned in the Gas Burners section. Do not

26
 DECREASE

OIL
METERING INCREASE INC.
VALVE

GAS VOLUME
INCREASE
CONTROL VALVE DEC.
FUEL UNIT DECR. DECREASE

MODULATING INCREASE
MOTOR
INCREASE

DECREASE

INCREASE RATE

AIR INLET
DECREASE RATE
571-0021
HOUSING ASSEMBLY DEC. 571-0028
90
CLOCKWISE
ROTATION
INC.

FIGURE 4-9 FIGURE 4-10

27
 SECTION 5
MAINTENANCE
A. GENERAL PROGRAMMING CONTROL
A maintenance program avoids unnecessary down time, This control requires no adjustment, nor should any
costly repairs, and promotes safety . It is recommended attempt be made to alter contact settings or timing logic.
that a record be maintained of daily, weekly, monthly, and Those programmers with contacts may require occasional
yearly maintenance activities. See letter J. cleaning. If so, follow instructions given in the manufacturer
s
Electrical and mechanical devices require systematic and bulletin. Never use abrasive materials.
The manufacturers
periodic inspection and maintenance. Any automatic bulletin also contains troubleshooting information. The
features do not relieve the operator from responsibility
, but f ame detector lens should be cleaned as often as condi-
rather free him from certain repetitive chores, providing tions demand.
time for upkeep and maintenance. A periodic safety check procedure should be established
Unusual noise, improper gauge reading, leak, sign of to test the complete safeguard system.Tests should verify
overheating, etc., can indicate a developing malfunction, safety shutdown with a safety lock out upon failure to ignite
requiring corrective action. the pilot or the main f ame, and upon loss of f ame. Each
of these conditions should be checked on a scheduled
basis. The safety check procedures are contained in the
WARNING manufacturers bulletin.

ONLY FACTORY AUTHORIZED BURNER SER VICE MOTORS

PERSONNEL SHOULD ST ART-UP, ADJUST, OR Supply voltage to the motor must not vary more than
SERVICE THIS EQUIPMENT 10 percent from nameplate ratings. At initial start-up and
regularly thereafter, check the motor current with an am-
meter while the burner is in highf re position. If the reading
CAUTION exceeds the nameplate rating plus service factor, determine
the cause and correct it. In dusty locations, clean the
Any cover plates, enclosures, or guards anchored motor regularly to assure adequate cooling. Lubricate in
to the burner, or any burner related equipment, accordance with the manufacturers instructions.
must remain in position at all times. Only during
maintenance and service shutdown can these
cover plates, enclosures, or guards be allowed to C. GAS SYSTEM
be removed.They must be replaced, and securely Check the gas train for leaks. Check the gas valves and
anchored before testing, adjusting, or running the verify the low and high gas pressure settings.
burner or burner related equipment.
SOLENOID VALVES
B. CONTROL SYSTEM A faint hum from the solenoid is normal when the coil
Most operating controls require very little maintenance is energized. Should the valve fail to operate, check that
beyond regular inspection. Examine electrical connections. there is voltage at the valve coil. If there is no voltage at
Keep the controls clean. Remove any dust from the interior coil, check for loose wiring connections. If there is proper
of the control. Covers should be left on controls at all times.voltage at the valve coil and the valve still fails to open,
Keep the control cabinet doors closed. Dust and dirt can replace the coil. Refer to manufacturers bulletin for correct
damage motor starters and relay contacts. Starter contacts procedure in coil replacement.
are plated with silver and are not harmed by discoloration. Should it become necessary to replace the complete
Never use f les or abrasive materials such as sandpaper valve, be sure that the f ow is in the direction of the arrow
on contact points. on the valve body.
Test for gas leaks and check valve action several times
to ensure proper operation before attempting to relight
WARNING burner.

WHEN REPLACING A CONTROL OR CLEANING CAUTION

CONTACTS, BE SURE TO DISCONNECT THE
MAIN POWER SUPPL Y SINCE THE CONTROL
IS ENERGIZED EVEN THOUGH THE BURNER
SWITCH IS OFF. MORE THAN ONE DISCONNECT
SWITCH MAY BE REQUIRED TO DISCONNECT
ALL POWER.
All power must be disconnected before
servicing valves.
MOTORIZED MAIN GAS VALVES
Should the valve fail to operate, check for voltage at valve.
Make certain that the main shut-off cock is closed prior to

28
testing. The actuator is not f eld repairable nor should it be diff culty in securing the electrodes in their clamps can be
disassembled. Replace the actuator if valve fails to oper- corrected by using light metal shims around the porcelain.
ate. Defective or cracked porcelains require replacement to
After replacement, cycle the valve with the fuel shut of f prevent short circuiting of the spark. A gradual wearing
to determine that it opens and closes. If the valve has a away of the electrode tips may require respacing of the
visual indicator, observe its position for correct operation. points or replacement of the electrode.
The pilot should be checked monthly for loosening of
D. OIL SYSTEM components and carbon buildup. Before removing the pilot,
Little maintenance is required on the oil systems other ensure that the fuel supply is shut off.
than cleaning the oil f lter. This procedure should be done On direct spark oil units, once you have removed the
at regular intervals. Increased inlet vacuum reading may drawer assembly, check the electrode to nozzle gap and
indicate a clogged f lter. Follow the strainer manufacturers adjust if necessary. Refer to the drawer assembly drawings
maintenance schedule. in the ADJUSTMENT section.
Maintenance checks on the f exible coupling between For burners equipped with a gas pilot, the pilot is located
the fuel unit and motor for alignment, tightness and wear on the side opposite to the main gas entrance. Close the
and oil piping connection tightness should also be made gas pilot cock. Disconnect the pilot gas supply line. Remove
at regular intervals. You access the coupling by removing the screws on the pilot access plate. Disconnect the high
the airbox cover and loosening the two setscrews on the voltage ignition cable by pulling it straight back, away from
f ex coupling. the pilot assembly. The pilot gun assembly will slide back
The oil nozzle should be checked. Inside the nozzle lies away from the f ame side of the burner. Once the pilot as-
a small screen that keeps out any particle not caught by sembly is clear of the burner head bracket, turn the pilot
the strainer. These particles will interfere with the normal assembly and retract it through the access hole. Inspect
oil f ow pattern exiting the nozzle. A distorted f ame can the electrode and adjust the gap if necessary. Thoroughly
indicate a clogged nozzle. Inspect and clean the nozzle clean and adjust the porcelain insulated electrodes. Cor-
and screen. To clean the screen, swirler, and tip, unscrew rect all variations from the clearance dimensions. If the
the tip from the nozzle body. Clean nozzle parts in solvent. insulation on the high-voltage cables becomes cracked or
Never use wire or sharp metal tools to clean the nozzle charred, install new cables. Ignition cable should not be
orif ce. A metal tool will distort the ori f ce and ruin the exposed to moisture, abrasion or rough handling. See that
nozzle. Reassemble the nozzle. The tailpiece must be the connectors are in perfect contact with the cable ends.
screwed in with the swirler seating tight against the tip to Unscrewing the snap portion of the connector will show
ensure proper atomization. Reassemble the nozzle into the whether this is true.
nozzle body. If a nozzle is replaced, it must be an identical
nozzle (make, size and spray angle). G. FLAME SCANNER
The scanner must be clean. Even a small amount of
E. DRAWER ASSEMBLY contamination will reduce the f ame signal. Wipe the
The drawer assembly may be removed for inspection scanner lens with a clean soft cloth. Check pilot andf ame
and service. signal strength.
1. Shut off burner, position switch in OFF position.
2. Shut off all electric power to the burner. H. BURNER MOUNTING INSPECTION
3. Disconnect the fuel lines from the drawer assembly The seal between the burner f ange and furnace front
access cover. plate must not permit combustion gases to escape. Periodic
4. After making note of where the bolts are located in inspection is important. If leaking occurs, refer to Section
relationship to the access cover slots, remove the drawer INSTALLATION for proper sealing procedure.
assembly access cover bolts. Pull the drawer partially out of
the housing. Reach inside to disconnect the ignition cables I. EXTENDED SHUTDOWN
from the electrodes for direct spark applications. Pull the When shutting down the burner for an extended period of
drawer assembly completely out of the housing. time, the operator should use the following general guide-
5. To reinstall the drawer assembly, insert it part way into the lines to protect the burner from its surrounding elements.
housing, connect the ignition cables if applicable, and seat This will add to the operating life of the burner:
the assembly fully. Install the access cover bolts loosely . 1. Turn the main electrical disconnect switch to the burner
Slide the cover the original location, and tighten the bolts. to OFF.
Reconnect the fuel lines. 2. Close all main fuel valves.
3. If the burner operates in a damp environment, cover it
F. IGNITION ELECTRODE,CABLE AND PILOT with plastic to protect all electrical components from mois-
Failure to keep electrodes clean and set in the proper ture.
position accounts for much faulty burner operation. Not 4. Remove the f ame safeguard and store in a dry atmo-
only must the gap be correct, but the electrode points must sphere.
be carefully located with respect to the nozzle. Sometimes

29
 J. MAINTENANCE FLOW CHART RECOMMENDED TEST SCHEDULE

ITEM SER VICE BY REMARKS

DAILY

Gauges, Monitors, Operator Make visual inspection and record readings in log.
and Indicators

Instrument and Equipment Operator Make visual check against recommended specif cations.
Settings

Low water, Fuel cut-off Operator Refer to instructions.

and Alarms

WEEKLY

Firing rate control Operator Verify factory settings

Igniter Operator Make visual inspection. Check f ame 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 Operator Read and log the f ame signal for both pilot and main f ame. Notify
Controls Service if readings are very high, very low, or f uctuating.

Linkages Operator Check all burner linkages for tightness. Tighten if required.

MONTHLY

Low Fan Pressure Operator Manually adjust until switch opens.

Interlock

High and Low Gas Operator Refer to instructions. Manually adjust until switch opens.
Pressure Interlocks

Scanner and Diffuser Operator Check, inspect and clean for soot buildup.

Pilot Assembly Operator Check for loosening of components, erosion or carbon buildup.

ANNUALLY

Strainer (Oil units) Operator Replace or clean the oil strainer element.

Impeller Operator Inspect and clean the combustion impeller.

Combustion Test Service Perform a complete combustion test. Adjust burner if necessary.
Technician Read and Log data.

Pilot turndown Test Service Required after any adjustment to f ame, scanner, or pilot
Technician adjustment

Operating Controls Service Refer to instructions.

Technician

30
 SECTION 6
TROUBLE SHOOTING
PROBLEM SOLUTION
1. No voltage at program relay power input terminals.
BURNER DOES NOT START
a. Main disconnect switch open.
b. Blown control circuit fuse.
c. Loose or broken electrical connection.

2. Program relay safety switch requires resetting.

3. Limit circuit not completed - no voltage at end of limit circuit program relay
terminal.
a. Pressure or temperature is above setting of operation control.
b. Water below required level.
Low-water light (and alarm horn) should indicate this condition.
Check manual reset button, if provided, on low -water control.
c. Fuel pressure must be within settings of low pressure and high
pressure switches.
d. Check burner air proving switch and high f re limit switch.

4. High or Low gas pressure - investigate and repair.

1. Lack of spark.
NO IGNITION
a. Electrode grounded or porcelain cracked.
b. Improper electrode setting.
c. Loose terminal on ignition cable; cable shorted.
d. Inoperative ignition transformer.
e. Insuff cient or no voltage at pilot ignition circuit terminal.

2. Spark but no f ame.

a. Lack of fuel - no gas pressure, closed fuel valve, empty tank, broken
line
b. Too much air f ow.
c. No voltage to pilot solenoid.
d. Defective pilot solenoid.
e. Improperly positioned electrode (Direct spark models).

3. Low f re switch open in low f re proving circuit.

a. Damper motor not closed, slipped cam, defective switch.
b. Damper jammed or linkage binding.

4. Running interlock circuit not completed.

a. Combustion proving switches defective or not properly set.
b. Motor starter interlock contact not closed.
5. Flame detector defective, sight tube obstructed, or lens dirty.

31
 TROUBLE SHOOTING
PROBLEM SOLUTION
1. Insuff cient pilot f ame.
PILOT FLAME, BUT NO
MAIN FLAME
2. Gas f red unit.
a. Manual gas cock closed.
b. Main gas valve inoperative.
c. Gas pressure regulator inoperative.

3. Oil f red unit.

a. Oil supply cut off by obstruction, closed valve, or loss of suction.
b. Supply pump inoperative.
c. No fuel. Broken, loose or missing oil pump coupling.
d. Main oil valve inoperative.
e. Check oil nozzle, gun and lines.

4. Flame detector defective, sight tube obstructed or lens dirty.

5. Insuff cient or no voltage at main fuel valve circuit terminal.

BURNER STAYS IN LOW 1. Pressure or temperature above modulating control setting.

FIRE

2. Manual-automatic switch in wrong position.

3. Inoperative modulating motor.

4. Defective modulating control.

5. Binding or loose linkages, cams, setscrews etc.

SHUTDOWN OCCURS 1. Loss or stoppage of fuel supply.

DURING FIRING
2. Defective fuel valve; loose electrical connection.

3. Flame detector weak or defective.

4. Scanner lens dirty or sight tube obstructed.

5. If the programmer lockout switch has not tripped, check the limit circuit for
an opened safety control.

32
 TROUBLE SHOOTING
PROBLEM SOLUTION
6. If the programmer lockout switch has tripped.
SHUTDOWN OCCURS
DURING FIRING (cont). a. Check fuel lines and valves.
b. Check f ame detector.
c. Check for open circuit in running interlock circuit.
d. The f ame failure light is energized by ignition failure, main f ame failure,
inadequate f ame signal, or open control in the running interlock circuit.

7. Improper air/fuel ratio.

a. Slipping linkage.
b. Damper stuck open.
c. Fluctuating fuel supply.
Temporary obstruction in the fuel line.
Temporary drop in gas pressure.

8. Interlock device inoperative or defective.

9. Air in the oil lines. Bleed lines.

MODULATING MOTOR 1. Manual-automatic switch in wrong position.

DOES NOT OPERATE
2. Linkage loose or jammed.

3. Motor does not drive to open or close during pre-purge or close on burner
shutdown.
a. Motor defective.
b. Loose electrical connection.
c. Damper motor transformer defective.

4. Motor does not operate on demand.

a. Manual/automatic switch in wrong position.
b. Modulating control improperly set or inoperative.
c. Motor defective.
d. Loose electrical connection.
e. Damper motor transformer defective.

33
NOTES:

34
 warranty policy

A. LIMITED WARRANTY
The Company warrants that at the time of shipment, the equipment manufactured by it shall be merchantable,
free from defects in material and workmanship and shall possess the characteristics represented in writing by the
Company. The Companys warranty is conditioned upon the equipment being properly installed and maintained
and operated within the equipments capacity under normal load conditions with competent supervised operators.
Equipment, accessories and other parts and components not manufactured by the Company are warranted only to
the extent of and by the original manufactures warranty to the Company; In no event shall such other manufacturers
warranty create any more extensive warranty obligations of the Company to the Buyer than the Companys warranty
covering equipment manufactured by the Company.

B. EXCLUSIONS FROM WARRANTY

(I) THE FOREGOING IS IN LIEU OF ALL OTHER WARRANTIES, ORAL OR EXPRESS OR IMPLIED, INCLUDING
ANY WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION OF THE EQUIPMENT. THERE ARE NO
EXPRESS WARRANTIES OTHER THAN THOSE CONTAINED HEREIN TO THE EXTENT PERMITTED BY THE
LAW. THERE ARE NO IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE. THE PROVISIONS
AS TO DURATION, WARRANTY ADJUSTMENT AND LIMITATION OF LIABILITY SHALL BE THE SAME FOR
BOTH IMPLIED WARRANTIES (IF ANY) AND EXPRESSED WARRANTIES.
(II) The Companys warranty is solely as stated in (a) above and does not apply or extend, for example, to:
expendable item; ordinary wear and tear; altered units; units repaired by persons not expressly approved by the
Company; materials not of the Companys manufacture; or damage caused by accident, the elements, abuse,
misuse, temporary heat, overloading, or by erosive or corrosive substances or by the alien presence of oil, grease,
scale, deposits or other contaminants in the equipment.

C. WARRANTY ADJUSTMENT
Buyer must make claim of any breach of any warranty by written notice to the Companys home off ce within thirty
(30) days of the discovery of any defect. The Company agrees at its option to repair or replace, BUT NOT INSTALL,
F.O.B. Companys plant, any part or parts of the equipment which within twelve (12) months from the date of initial
operation but no more than eighteen (18) months from date of shipment shall prove the Companys satisfaction
(including return to the Companys plant, transportation prepaid, for inspection, if required by the Company) to be
defective within the above warranty. Any warranty adjustments made by the Company shall not extend the initial
warranty period set forth above. Expenses incurred by Buyer in replacing or repairing or returning the equipment or
any part or parts will not be reimbursed by the Company.

D. SPARE AND REPLACEMENT PARTS WARRANTY ADJUSTMENT

The Company sells spare and replacement parts. This subparagraph (d) is the warranty adjustment for such parts.
Buyer must make claim of any breach of any spare or replacement parts by written notice to the Companys home
off ce within thirty (30) days of the discovery of any alleged defect for all such parts manufactured by the company.
The Company agrees at its option to repair or replace, BUT NOT INSTALL, F.O.B. Companys plant, any part or
parts or material it manufacture which, within one (1) year from the date of shipment shall prove to Companys
satisfaction (including return to the Companys plant, transportation prepaid, for inspection, if required by the
Company) to be defective within this part warranty. The warranty and warranty period for spare and replacement
parts not manufactured by the company (purchased by the Company, from third party suppliers) shall be limited to
the warranty and warranty adjustment extended to the Company by the original manufacturer of such parts; In no
event shall such other manufacturers warranty create any more extensive warranty obligations of the Company to
the Buyer for such parts than the Companys warranty adjustment covering part manufactured by the Company as
set forth in this subparagraph (d). Expenses incurred by Buyer in replacing or repairing or returning the spare or
replacement parts will not be reimbursed by the Company.

35
E. LIMITATION OF LIABILITY
The above warranty adjustment set forth Buyers exclusive remedy and the extent of the Companys liability
for breach of implied (if any) and express warranties, representations, instructions or defects from any cause in
connection with the sale or use of the equipment. THE COMPANY SHALL NOT BE LIABLE FOR ANY SPECIAL,
INDIRECT OR CONSEQUENTIAL DAMAGES OR FOR LOSS, DAMAGE OR EXPENSE, DIRECTLY OR
INDIRECTLY ARISING FROM THE USE OF THE EQUIPMENT OR FROM ANY OTHER CAUSE WHETHER
BASED ON WARRANTY (EXPRESS OR IMPLIED) OR TORT OR CONTRACT, and regardless of any advices or
recommendations that may have been rendered concerning the purchase, installation, or use of the equipment.

36
 START-UP / SERVICE
REPORT
The following information should be f lled in by the service technician at start-up or after any adjustment to the burner.

A copy of the start-up report MUST be returned to CB in order to validate the warranty of the burner.

Burner Model Serial Number Start-up Date

GAS OIL
Test Conducted Low 50% High Low 50% High Control Checks Test Set Point
Firing Rate MMBtu / gph Low Water Cut Off
Stack Temp (Gross) oF Aux. LWCO
Room Temp oF High Water Cut Off
Operating Limit
O2%
High Limit
CO2%
Operating Control
CO (PPM)
Stack Temp Interlock
NOx (PPM) Flame Failure
Smoke (Bacharach) Combustion Air Switch
Combustion Eff.% High Purge Switch
Stack Draft "W.C. Low Fire Interlock
Furnace Pressure "W.C. Oil Pressure Switch
Oil Valve with P.O.C.
Blast tube Pressure "W.C.
Interlock
Steam Pressure PSIG
High Gas Pressure
Water Temperature oF Switch
Supply oil pressure PSIG Low Gas Pressure
Switch
Return oil pressure PSIG
Gas Valve P.O.C.
Vacuum oil pump "HG Interlock
Oil Temperature Pilot Turndown Test
Atom. air pressure Flame Signal Pilot
Gas Pressure @ Burner Inner Manifold
Manifold "W.C. Outer Manifold
Center Gas pressure "W.C. (For Low NOx Burners)
Gas Pressure @ Regulator Inlet PSIG Blast Tube Temp.
Interlock
Gas Pressure @ Regulator Outlet PSIG
FGR Line Purge Switch
Pilot Gas Pressure @ Regulator Outlet "W.C.
FGR Valve P.O.C.
Flame Signal Main Low 50% High Switch

Voltage Amperage Adjusted by:

Electric Motors L1 L2 L3 L1 L2 L3 Date:
Control Voltage
Blower Motor Accepted by:
Air Compressor
Air-Oil or Metering (Signature Required)

37
 PRODUCT SATISFACTION
SURVEY

Burner Model Serial Number

As a requirement of our ISO certif cation, please f ll-in this form and return to CB Prof re.
Please rate your satisfaction with the following:
Poor Good Excellent
Delivery time
Apperance of equipment after delivery
Piping and tubing
Wiring
All components arrived with equipment
Ease of start-up
Performance of equipment
Quality of information provided
Sales
Engineering
Service
Parts
Overall way any problems were handled

Comments:

Date: By:

38
Notes
 e-mail: info@cleaverbrooks.com
Web Address: http://www.cleaverbrooks.com