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Industrial combustion V Series Installation, Operation And Service Manual

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V/LNV SERIES
Installation, Operation, and Service
ONLY FACTORY AUTHORIZED BURNER SERVICE
PERSONNEL SHOULD START UP, ADJUST, OR SER-
VICE THIS EQUIPMENT
Manual
WARNING
! DANGER
IC-SA-1511
02/2014

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Summary of Contents for Industrial combustion V Series

  • Page 1 V/LNV SERIES Installation, Operation, and Service Manual WARNING ! DANGER ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST, OR SER- VICE THIS EQUIPMENT IC-SA-1511 02/2014...
  • Page 3 V/LNV SERIES Installation, Operation, and Service Manual 656-10219-000 Manual Number: IC-SA-1511 Release Date: September 2010...
  • Page 4 Copyright © 2014 by Industrial Combustion All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior written consent of Industrial Combustion. Industrial Combustion...
  • Page 5 B139 (for oil burners) codes shall prevail. Oil and gas burning equipment shall be connected to flues having sufficient draft at all times to assure safe and proper operation of the burner. The V series burners are designed to burn either gas or light oil No. 1 or 2 as defined by ASTM D396-2010 specifications. Do...
  • Page 6 Standard Specifications for VG-VL-VLG Series: Gas, #2 Oil, Gas/Oil Configuration #2 Oil Standard Blower Blower Remote Input Input Furnace Gas Train Min. Gas Motor Motor Oil Pump Burner MBtu/ @80% Pressure Pipe Size Pressure Blower Motor Model Eff. (“W.C.) Motor HP (in.) (“w.c.) Volt/PH 60 Hz.
  • Page 7 <30 PPM Low NOx Standard Specifications for LNVG-LNVLG Series: Gas, Gas/Oil Configuration #2 Oil Standard Blower Remote Input Input Furnace Gas Train Min. Gas Line Motor Oil Pump Burner MBtu/ @80% Pressure Pipe Size Pressure Piping Blower Motor Model Eff. (“W.C.) Motor HP (in.)
  • Page 8 V Series Standard Dimensions - Uncontrolled NOx Configuration A 3/4" 4" H DIA I B.C. H DIA 4X Ø3/4 I B.C. Accompanying dimensions are for layout purposes only. Burner Frame Size & Model Number Size 1 Size 2 Size 3...
  • Page 9 V Series Standard Dimensions - <30 PPM Low NOx Configuration A 3/4" 4" Y DIA 8X Ø3/4 Z B.C. 8X Ø3/4 Z B.C. Y DIA H DIA 4X Ø.75 I B.C. Accompanying dimensions are for layout purposes only. Burner Frame Size & Model Number...

  • Page 11: Table Of Contents

    V/LNV Series Table of Contents Introduction 1-1 CHAPTER 1 1.1 — Overview 1-1 1.2 — Description 1-1 1.3 — Operating Controls 1-2 1.3.1 — Control Panel 1-2 1.3.2 — Flame Safeguard Controls 1-3 1.3.3 — Firing Rate Controls (LHL & Full Modulation Burners) 1-3 1.4 —...
  • Page 12 2.4.2 — Combustion Chamber Dimensions - Inverted/ Standard Config. Firetube 2-3 2.4.3 — Combustion Chamber Drawings - Watertube/ Cast Iron Boiler Applications 2-4 2.4.4 — Combustion Chamber Dimensions - Inverted/ Standard Config. Watertube 2-5 2.5 — Installation 2-6 2.6 — Packing Plastic Insulation Around Oven (If Dry Oven Supplied) 2-7 2.7 —...
  • Page 13 3.7 — Safety Shutdown 3-5 3.8 — Startup and Operating 3-6 3.8.1 — Gas Burners 3-6 3.8.2 — Oil Burners 3-7 3.8.3 — Combustion Gas-Oil Burners 3-8 3.8.4 — Fuel Chart Comparison for O - Excess Air - CO 3.9 — Normal Operation 3-10 3.10 —...
  • Page 14 4.5.9 — Full Modulation Gas Burner Adjustment 4-16 4.5.10 — Low NOx Full Modulation Combination Gas Burner Adjustment 4-16 4.6 — Oil System 4-17 4.6.1 — On-Off Oil Burner Adjustment 4-18 4.6.2 — Low-High-Off/Low Oil Burner Adjustment 4-18 4.6.3 — Full Modulation Oil Burner Adjustment 4-18 4.7 —...
  • Page 15 5.9 — Diffuser 5-5 5.10 — Firing Rate Controls 5-5 5.11 — Burner Mounting Inspection 5-5 5.12 — Oil System 5-5 5.13 — Gas System 5-5 5.13.1 — Solenoid Valves 5-6 5.13.2 — Motorized Main Gas Valves 5-6 5.14 — Electrical System 5-6 5.14.1 —...
  • Page 16 7.4 — FGR Control Valve 7-3 7.4.1 — Low NOx Full Modulation Combination Gas-Oil Burner Adjustment 7-4 7.5 — Air/FGR Damper Assembly 7-5 7.6 — Stack Temperature Interlock 7-5 7.7 — Blast Tube Temperature Interlock 7-5 WARRANTY POLICY STARTUP/SERVICE REPORT IC-SA-1511 (02/2014) V/LNV Series Manual...

  • Page 17: Introduction

    1.2 — Description The Industrial Combustion V series burners are designed to operate with gas and light oil. The burners are designed for automatic, unattended operation except for periodic inspection and maintenance. The burner and control panel components require little attention except for occasional cleaning.

  • Page 18: Operating Controls

    Introduction The burners are available in the following configurations: Standard Configuration Optional Configuration V13-25 On-Off Low-High-Off (LHO), Low-High-Low (LHL) or Full Modulation V30-63 Low-High-Off (LHO) Low-High-Low (LHL) or Full Modulation V70-168 Full Modulation None 1.3 — Operating Controls 1.3.1 — Control Panel The burner control panel may be integral to the burner or remote, and contains: a flame safeguard programming control, motor relays (starters), and terminal strips mounted internally on a panel subbase.

  • Page 19: Flame Safeguard Controls

    Introduction 1.3.2 — Flame Safeguard Controls The flame safeguard controls the burner's operating sequence: pre purge, trial for ignition, main flame and shutdown. This safety control also includes flame detection system to confirm proper operation or cause a manual-reset lockout in the event of a pilot or main flame failure. External controls connected to the flame control's limit circuit, such as the boiler operating control, will trigger normal burner startup, and upon reaching operating set point, normal burner shutdown.

  • Page 20: Boiler Room Combustion Air

    Introduction 1.4.1 — Boiler Room Combustion Air When determining boiler room air requirements, the size of the room, airflow, and velocity of air must be reviewed as follows: fpm: Feet per Minute cfm: Cubic Feet per Minute Two (2) permanent air supply openings in the outer walls of the boiler room are recommended.

  • Page 21: Firing Head

    Introduction 1.5 — Firing Head Two side access covers provide access to the firing head internal components. The firing head configuration is dependent upon the heat exchanger it is attached to. Figure 1-1 shows a a radial spud firing head typically used on watertube applications while Figure 1-2 illustrates a typical arrangement for firetube applications.

  • Page 22: Oil System

    Introduction 1.6 - Oil System The V series burners pump high pressure fuel oil to the spray nozzle resulting in combustion-ready finely atomized oil spray. 1.6.1 — Oil System Components Component Description Fuel Unit Standard V13-55 have an oil pump flex-coupled to the blower motor; these units may be optionally equipped with a remote pump.
  • Page 23 Introduction NOZZLE N.C. OIL VALVES FUEL UNIT OIL PRESSURE OIL SUPPLY REGULATOR N.O. OIL VALVE OIL RETURN TO TANK FIGURE 1-4. LHL Oil System with Integral Pump & Simplex Nozzle (V13-34) N.C. OIL VALVES NOZZLE FUEL UNIT SUPPLY OIL PRESSURE REGULATOR N.O.
  • Page 24 Introduction MODULATING MOTOR PRESSURE SWITCH NOZZLE FUEL UNIT PRESSURE TAP FUEL UNIT OIL SUPPLY OIL RETURN TO TANK METERING VALVE FIGURE 1-6. Full Modulation Oil System with Integral Pump & Simplex Nozzle (V13-34) NODULATING MOTOR FUEL UNIT PRESSURE TAP NOZZLE FUEL UNIT PRESSURE TAP FUEL UNIT...

  • Page 25: Operation

    Introduction MODULATING MOTOR NOZZLE OIL SUPPLY TO NOZZLE SUPPLY PRESSURE SWITCH FUEL UNIT PRESSURE TAP OIL RETURN TO TANK N.C. METERING VALVES REMOTE FUEL VALVE UNIT FIGURE 1-8. Full Modulation Oil System with a Remote Pump (V60-168) 1.6.2 — Operation Fuel oil is delivered to the fuel pump, either by gravity, fuel pump suction, or by a circulating pump, through a fuel oil filter.

  • Page 26: Main Gas Train Components

    Introduction valve. Safety shutoff gas valves are wired into the programming control to automatically open and close at the proper time in the operating sequence. 1.7.1 — Main Gas Train Components Depending upon the requirements of the regulating authority, the gas control system and gas train may consist of some, or all, of the following items: Main Gas Train Component...
  • Page 27 Introduction FIGURE 1-9. Typical Gas Train for On-Off System (V13-25) FIGURE 1-10. Typical Gas Train for LHO System (V13-34) IC-SA-1511 (02/2014) 1-11 V/LNV Series Manual...
  • Page 28 Introduction FIGURE 1-11. Typical Gas Train for Full Modulation System (V13-34) FIGURE 1-12. Typical Gas Train for LHO/LHL Systems (V35-63) & Full Modulation Systems (V35-168) 1-12 IC-SA-1511 (02/2014) V/LNV Series Manual...

  • Page 29: Pilot Gas Train Components

    Introduction 1.7.2 — Pilot Gas Train Components Models VL 60-168 as well as all VG and VLG models are supplied with a gas pilot system. Oil only models VL 13-55 are supplied with direct spark ignition. Component Description Gas Pilot Valve A solenoid valve that opens during the ignition period to admit fuel to the pilot.

  • Page 31: Installation

    2.2 — Draft Conditions A boiler or other heating vessel fired with a V series burner does not depend on chimney draft for proper combustion air. Combustion air is supplied by the burner forced draft blower providing adequate air for any normal combustion condition.

  • Page 32: Combustion Chamber Recommendations

    Installation 2.4 — Combustion Chamber Recommendations 2.4.1 — Combustion Chamber Drawings - Firetube Boiler Application 1.5" - 2.0" C (MIN) FIGURE 2-1. Standard Configuration for Firetube Boiler 1.5" - 2.0" C (MIN) FIGURE 2-2. Inverted Configuration for Firetube Boiler IC-SA-1511 (02/2014) V/LNV Series Manual...
  • Page 33 Installation 2.4.2 — Combustion Chamber Dimensions - Inverted and Standard Configuration Firetube Boiler Combustion Burner Chamber Model Min. Length IC-SA-1511 (02/2014) V/LNV Series Manual...

  • Page 34: Combustion Chamber Drawings - Watertube/ Cast Iron Boiler Applications

    Installation 2.4.3 — Combustion Chamber Drawings - Watertube/ Cast Iron Boiler Application(s) C (MIN) STANDARD FIREBRICK FLOOR BLOCK INSULATION FIGURE 2-3. Standard Configuration for Watertube/ Cast Iron Boiler C (MIN) STANDARD FIREBRICK FLOOR BLOCK INSULATION FIGURE 2-4. Inverted Configuration for Watertube/ Cast Iron Boiler IC-SA-1511 (02/2014) V/LNV Series Manual...

  • Page 35: Combustion Chamber Dimensions - Inverted/ Standard Config. Watertube

    Installation 2.4.4 — Combustion Chamber Dimensions - Inverted/ Standard Config. Watertube/ Cast Iron Boiler Combustion Combustion Burner Chamber Chamber Model Min. Width Min. Length 6.63 6.63 6.63 6.63 6.63 6.63 6.63 6.63 13.5 6.63 13.5 6.63 13.5 6.63 13.5 6.63 13.5 6.63 13.5...

  • Page 36: Installation

    Installation Refer to pages 2-2 through 2-5 for combustion chamber dimensions for firetube and watertube boiler applications. Combustion chamber dimensions should be adequately sized to prevent flame impingements. A dry oven refractory is required only to protect surfaces not adequately protected by free circulating water. Basic objectives include: •...

  • Page 37: Packing Plastic Insulation Around Oven (If Dry Oven Supplied)

    2.00 SECTION A-A FIGURE 2-5. V Series Refractory Dimensions 2.6 — Packing Plastic Insulation Around Oven (If Dry Oven is Supplied) The area between the outside circumference of the dry oven and existing refractory should be packed with Kaiser Refractory Mono T-9 Airset or equal within two hours after coating the dry oven with Trowleze. From inside the furnace, ram the plastic refractory from the front to the rear, parallel to the outside surface of the dry oven.

  • Page 38: Oil Piping

    Number of fittings. Although the gear type pumps used on the V series burners are capable of developing higher suction, it is not desirable to operate above 15 inches of mercury vacuum. If the vacuum is greater, flow may be erratic.

  • Page 39: Two Pipe - Multiple Burner System

    30% service factor. The burner return lines feed into the common supply line. NOTE: Industrial Combustion recommends that all oil firing burners be equipped with an oil strainer (if not included with the burner) to prevent particles from clogging the nozzle. It is essential to follow the strainer manufacturer’s maintenance schedule to ensure proper filtration.
  • Page 40 Installation FIGURE 2-7. Multiple Burners with Separate Suction Lines FIGURE 2-8. Typical Oil Loop for Multiple Burners with Transfer Pump 2-10 IC-SA-1511 (02/2014) V/LNV Series Manual...

  • Page 41: Gas Piping

    Installation FIGURE 2-9. Typical Installation Using Day Tank FIGURE 2-10. Typical Flooded Loop System 2.8 — Gas Piping Refer to Figures 1-9 through 1-12 for typical gas piping arrangements. Normally, the control train is ordered to suit a particular code or insurance regulation, such as UL/cUL, FM, or GAP. Gas service and house piping must supply the quantity of gas demanded by the unit at the pressure required at the burner gas train inlet.

  • Page 42: Installation Checklist

    Installation All piping must be in strict accordance with applicable codes, ordinances, and regulations of the supplying utility. In the absence of other codes, piping should be in accordance with the following standards: “National Fuel Gas Code” NFPA No. 54, ANSI No. Z223-1. Gas train components upstream of the butterfly valve are shipped loose.

  • Page 43: Firing Modes

    Installation 2.10 — Firing Modes ON-OFF OPERATION Combustion Air Pressure Atomization: Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to the nozzle. Oil Safety shut off valve(s) are provided to initiate the flow of flow rate is fixed based on pump oil pressure gas.
  • Page 44 Installation LOW-HIGH-OFF OPERATION - LOW or 60% DAMPER PURGE Combustion Air Two safety shut off valves are Pressure Atomization: Two solenoid type safety A two blade damper is controlled provided to initiate the flow of gas. shut off oil valves initiate the flow of oil from the by a two position, spring return The primary is a diaphragm or high pressure pump to the nozzle.
  • Page 45 Installation LOW-HIGH-OFF OPERATION - OPEN DAMPER PURGE Combustion Air Pressure Atomization: Two solenoid type safety Safety shut valve(s) shut off oil valves initiate the flow of oil from the provided to initiate the flow of gas. high pressure pump to the nozzle. The oil pump A two blade damper is controlled has a built in solenoid controlled two level The primary is a diaphragm or...
  • Page 46 Installation LOW-HIGH-LOW MOD - LOW or 60% DAMPER PURGE Combustion Air Pressure Atomization: Two solenoid type safety A two blade damper is controlled shut off oil valves initiate the flow of oil from the by a two position, spring return Safety shut off valve(s) are provided high pressure pump to the nozzle.
  • Page 47 Installation LOW-HIGH-LOW MOD - OPEN DAMPER PURGE Combustion Air Pressure Atomization: Two solenoid type safety A two blade damper is controlled Safety shut valve(s) shut off oil valves initiate the flow of oil from the high by a two position, spring return provided to initiate the flow of pressure pump to the nozzle.
  • Page 48 Installation FULL MODULATION - LOW or 60% DAMPER PURGE Combustion Air Pressure Atomization: Two solenoid safety shut A two blade damper is controlled off valves initiate the flow of oil from the high by a proportional modulating pressure pump to a return flow nozzle. In the return actuator motor) with...
  • Page 49 Installation FULL MODULATION - LOW or 60% DAMPER PURGE Combustion Air On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut-off valve. SAFETY SHUT-OFF Options are available for 4-20mA NOZZLE VALVES...
  • Page 50 Installation FULL MODULATION - OPEN DAMPER PURGE Combustion Air Pressure Atomization: Two solenoid type safety shut off oil valves initiate the flow of oil A two blade damper is controlled by from the high pressure pump to a return flow a proportional modulating actuator nozzle.
  • Page 51 Installation FULL MODULATION - OPEN DAMPER PURGE Combustion Air On models with a simplex nozzle oil is diverted from the supply line through the meter and back to the pump before the first safety shut off valve. Options are available for 4-20amp SAFETY SHUT-OFF NOZZLE...
  • Page 52 Installation PARALLEL POSITIONING Combustion Air Pressure Atomization: Two solenoid type safety shut off oil valves initiate the flow of oil from the high pressure pump to a return flow nozzle. In the return line from the nozzle is an NOTE: Parallel Positioning systems adjustable oil metering valve which limits the incorporate independent actuators Safety shut off valve(s) are provided...

  • Page 53: Operation

    Operation CHAPTER 3 3.1 — Preparations for Starting When the installation is complete and all electrical, fuel, water, and vent stack connections are made, make certain these connections are tight. The operator should become familiar with the burner, boiler controls and components.

  • Page 54: Oil Flow

    Operation 3.1.1 — Oil Flow If the oil supply tank is below the level of the fuel oil unit, it is recommended that the suction line be primed with oil prior to starting the pump to avoid the possibility of damage to the pump through operation without lubrication.

  • Page 55: Burner Settings

    Operation When the conditions covered above and in Chapter 2 are assured, the burner is ready for firing. 3.1.5 — Burner Settings To ensure reliable and safe burner performance, the location and gap setting of the electrode for direct- spark igniters, and the relative positions of the burner nozzle, diffuser, and air baffle components must be correctly set.

  • Page 56: Gas Fired

    Operation 3.2.1 — Gas Fired Close the pilot and main line manual gas valves. Start the burner and at time of pilot trial with just the electrical ignition system energized. The flame relay should not pull in (should not be energized). Upon completion of a successful test, proceed with startup procedures.

  • Page 57: Automatic Shutdown

    Operation When firing oil, open the manual oil valves. When firing on gas, open the main manual gas valve. When firing on gas, manually reset the high and low gas pressure switches (if applicable). Place the gas-oil selector switch (if applicable) in position for the desired fuel. With all limit and operating controls calling for heat, the burner will follow the flame safeguard sequence.

  • Page 58: Startup And Operating

    Operation Warning Should a starting failure occur for any reason, combustible fumes may fill the combustion chamber. Never attempt to re-light the burner under these conditions. The combustion chamber must first be purged before re- lighting. Warning Keep fingers away from the combustion air intake below the damper. The damper is actuated with sufficient force to cause severe injury.

  • Page 59: Oil Burners

    Operation Check to see that the gas valve has closed tightly. If ignition does not occur, turn the burner switch “OFF” and allow the programmer to recycle for a new ignition trial. Turn the burner “ON” and after pilot ignition when the flame relay pulls in, the slow opening, motorized, main gas valve is energized.

  • Page 60: Combustion Gas-Oil Burners

    Operation Set the “ON-OFF” switch to “ON.” The burner will start and pre-purge. After pre-purge, the ignition transformer will direct spark. If the flame detector proves the presence of a satisfactory pilot, the programmer will proceed to main flame ignition. Make initial air shutter settings for smooth ignition.

  • Page 61: Fuel Chart Comparison For O - Excess Air - Co

    Operation BLOWER MOTOR ACCESS COVER IMPELLER WHEEL FLEXIBLE 656-10212-000 COUPLING FIGURE 3-1. Blower Motor and Flexible Coupling 3.8.4 — Fuel Chart Comparison for O - Excess Air - CO Excess Air Natural Gas Propane No. 2 Oil 11.4 13.3 14.9 11.2 13.0 14.5...

  • Page 62: Normal Operation

    Operation Excess Air Natural Gas Propane No. 2 Oil 13.0 147.0 14.0 181.0 15.0 226.0 NOTE: Carbon Monoxide (CO) PPM should be attainable at levels below 50 PPM on most gun style burners regardless of the fuel being used. In some instances this is not possible due to variables specific to a particular application (ie.

  • Page 63: Adjustments

    Adjustments CHAPTER 4 4.1 — Overview While each burner is tested at the factory for correct operation before shipment, variable conditions such as burning characteristics of the fuel used and operating load conditions may require further adjustment after installation to assure maximum operating efficiency. Prior to placing the boiler into initial service, a complete inspection should be made of all controls, connecting piping, wiring and all fastenings such as nuts, bolts and setscrews to be sure that no damage or misadjustments occurred during shipping and installation.

  • Page 64: Smoke Measurement

    .04% CO (400 ppm). A high-fire reading typically is 3% to 5% O and less than .04% CO. The V series burners are capable of operating at low excess air and less than 50 ppm CO levels at all firing rates.

  • Page 65: Oil Fired

    Adjustments Upon completion of successful test, proceed with startup procedures. 4.3.2 — Oil Fired Disconnect the electrical power to the burner. Disconnect the electric oil safety shutoff valve. Reconnect electric power. Close the pilot line manual gas valve, if used. Start the burner and at the time of pilot trial, with just the electrical ignition system energized, the flame relay should not pull in.

  • Page 66: Direct Spark Oil Only (Vl) Adjustment (V13-55)

    Adjustments When the pilot comes on, put the programmer timer on pilot hold by placing the “RUN-TEST” switch on the flame safeguard to the “TEST” position. Check the flame signal strength. Adjust the flame signal by increasing or decreasing pilot gas pressure with the regulator spring.
  • Page 67 Adjustments For burners with a gas pilot: a. Disconnect the pilot line and loosen the locking screws on the pilot access cover located on the side of the firing head. b. Disconnect the high voltage ignition cable by pulling it straight back, away from the pilot assembly.The pilot assembly will slide back and away from the diffuser.

  • Page 68: Drawer Assemblies For Firetube Boiler Applications

    Adjustments 4.4.5 — Drawer Assemblies for Firetube Boiler Applications .26" REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4-3. Drawer Assembly for (VG) Gas Only (V13-34) - Firetube 5/32" BETWEEN INNER EDGES OF ELECTRODE WIRES .25" NOZZLE TIP TO OUTER EDGE OF 7/16"...
  • Page 69 Adjustments .16" REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4-6. Drawer Assembly for (VG) Gas Only (V35-55) - Firetube 7/16" FROM CENTER OF OIL NOZZLE TIP 5/32" BETWEEN TO BOTTOM EDGE INNER EDGES OF .25" NOZZLE TIP OF ELECTRODE WIRES ELECTRODE WIRES TO OUTER EDGE OF...
  • Page 70 Adjustments .16" REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4-9. Drawer Assembly for (VG) Gas Only (V60-110) - Firetube .00" FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER .16" REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4-10.

  • Page 71: Drawer Assemblies For Watertube/Cast Iron Boiler Applications

    Adjustments .00" FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER .15" REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE FIGURE 4-12. Drawer Assembly for (VLG) Gas/Oil (V120-168) - Firetube 4.4.6 — Drawer Assemblies for Watertube/Cast Iron Boiler Applications 1.83"...
  • Page 72 Adjustments 5/32" BETWEEN INNER EDGES OF ELECTRODE WIRES 7/16" FROM CENTER OF OIL NOZZLE TIP TO BOTTOM EDGE .25" NOZZLE TIP OF ELECTRODE WIRES TO OUTER EDGE OF ELECTRODE WIRES .25" FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 1.89" REAR FACE 656-10215-000 OF DIFFUSER TO FRONT FACE OF...
  • Page 73 Adjustments 5/32" BETWEEN INNER EDGES OF 7/16" FROM CENTER ELECTRODE WIRES OF OIL NOZZLE TIP .25" NOZZLE TIP TO BOTTOM EDGE TO OUTER EDGE OF OF ELECTRODE WIRES ELECTRODE WIRES .25" FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 1.89" REAR FACE OF DIFFUSER TO 656-10215-000 FRONT FACE OF...
  • Page 74 Adjustments .00" FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 1.83" REAR FACE OF DIFFUSER TO FRONT FACE OF 656-10215-000 AIR BAFFLE FIGURE 4-20. Drawer Assembly for (VLG) Gas/Oil (V60-110) - Watertube/ Cast Iron 1.92" REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656-10215-000...

  • Page 75: Gas System

    Adjustments 4.5 — Gas System Refer to the burner data plate located inside the control panel door. The nameplate will list the following burner information: • burner and control voltage • phase • cycle • motor amperage • maximum and minimum fuel input settings •...

  • Page 76: High Gas Pressure Switch

    Adjustments 4.5.5 — High Gas Pressure Switch Turn the adjusting screw until the indicator moves to a pressure setting slightly above the maximum operating gas pressure. The control will break a circuit if pressure exceeds this value. The control should be adjusted to prevent operation with excessive gas pressure, but not at a pressure so close to normal operating pressure that unnecessary shutdowns occur.

  • Page 77: Low-High-Off/Low Gas Burner Adjustment

    Adjustments spring hold the valve closed. On call for heat, the controller contacts close and the coil is energized. This pulls the plunger to the “UP” position, opening the bleed port and closing the supply port. The gas in the top of the valve flows out through the bleed port.

  • Page 78: Full Modulation Gas Burner Adjustment

    Adjustments 4.5.9 — Full Modulation Gas Burner Adjustment The burner adjustments on a full modulation gas burner consist of the gas pressure regulator, butterfly gas valve, low nad high gas pressure switches (model V30-168), and air dampers. Open the manual gas shutoff cocks. Check the gas pressure at the inlet of the regulator and the pressure downstream of the regulator.

  • Page 79: Oil System

    Adjustments With an analyzer in the stack, adjust the FGR valve cam screw to obtain <30 ppm NOx levels. NOTE: Do not adjust the burner below <20 ppm. Unstable combustion and high CO emissions will result. Monitor O and CO levels during this process. The introduction of FGR into the combustion chamber will lower the flue O levels.

  • Page 80: On-Off Oil Burner Adjustment

    Adjustments 4.6.1 — On-Off Oil Burner Adjustment On-Off burners use the Suntec B2TC-8931 oil pump model. High-fire pressure adjustment is 200 - 300 psi (solenoid energized), and low-fire pressure adjustment is 100 - 200 psi (solenoid de-energized). Briefly push in the starter contact and release to ensure that the blower motor and oil pump are rotating in the correct direction.

  • Page 81: Combination Gas-Oil System

    Adjustments installed in the return line to monitor the oil pressure. At low-fire, the pressure range in the return line should be between 40 and 80 PSI with the oil metering valve position set between 6 and 8 on the scale. At high- fire, the return line pressure will vary from 135 to 200 PSI dependent upon the brand of the oil nozzle.

  • Page 82: On-Off Combination Gas-Oil Burner Adjustment

    Adjustments 4.7.1 — On-Off Combination Gas-Oil Burner Adjustment Turn the fuel selector switch to the “OIL” position. Turn the burner switch to the “ON” position. Proceed with startup and adjustments using the same procedures as explained in Section 4.5.1. After the system has been completely adjusted for oil firing, place the burner switch to “OFF” and position the fuel selector switch to “GAS”.

  • Page 83: Cam Trim Adjustment

    Adjustments The modulating motor will be stopped at the end of its stroke by an internal limit switch. Combustion gas analysis indicates the air to fuel ratio and the degree of complete combustion. The closer the rod comes to parallel with the lever, the slower the rod moves. The angles of the driven levers on the jackshaft can be adjusted to vary the rate of change.

  • Page 84: Parallel Positioning Adjustment

    4.9 — Air and Fuel Controls 4.9.1 — Air Flow Control The V series burners have a two-blade air shutter design. Both blades are coupled together and are attached to the modulation motor. Changing the positions of the linkage rods on the linkage control arms will change the way the damper blades open and close.

  • Page 85: Fuel And Air Flow Settings

    Adjustments 4.9.2 — Fuel and Air Flow Settings Fuel and air flow rates can be individually adjusted at low-fire and high-fire to achieve rated heat input, firing rate turndown, optimum efficiency, safe operation, and the ability to cope with environmental changes (air temperature, humidity, barometric pressure), and fuel property changes.
  • Page 86 Adjustments OPEN OPEN FRONT REAR AIR SHUTTER AIR SHUTTER FIGURE 4-26. Front and Rear Shutters 4-24 IC-SA-1511 (02/2014) V/LNV Series Manual...

  • Page 87: Maintenance

    Maintenance CHAPTER 5 5.1 — Overview Warning Any cover plates, enclosures, or guards anchored to the burner, or any burner related equipment, must remain in position at all times. Only during maintenance and service shutdown can these cover plates, enclosures, or guards be allowed to be removed.

  • Page 88: Programming Control

    Maintenance Warning When replacing a control or cleaning contacts, be sure to disconnect the main power supply since the control is energized even though the burner switch is “OFF.” More than one disconnect switch may be required to disconnect all power. 5.2.1 —...

  • Page 89: Impeller And Inlet Cone

    5.4 — Impeller and Inlet Cone 5.4 — Impeller and Inlet Cone Proper clearance between the impeller and the inlet housing set at 3/8” nominal. Adjust the inlet cone so it is centered in the inlet of the impeller and tighten the bolts. There should be no contact between the inlet cone and the impeller.

  • Page 90: Flame Scanner

    Maintenance For burners equipped with a gas pilot, the pilot is located on the side opposite to the main gas entrance. Close the gas pilot cock. Disconnect the pilot gas supply line. Remove the screws on the pilot access plate. Disconnect the pilot gas supply line.

  • Page 91: Diffuser

    5.9 — Diffuser 5.9 — Diffuser The diffuser is factory set and does not require attention under normal operating conditions. If fouled with carbon, the diffuser should be removed for cleaning: First remove the electrode leads, the gas pilot assembly, air and oil tubes before you attempt to remove the diffuser.

  • Page 92: Solenoid Valves

    Maintenance 5.13.1 — Solenoid Valves A faint hum from the solenoid is normal when the coil is energized. Should the valve fail to operate, check that there is voltage at the valve coil. If there is no voltage at the coil, check for loose wiring connections. If there is proper voltage at the valve coil and the valve still fails to open, replace the coil.

  • Page 93: Failure To Light Main Flame

    5.15.2 — Failure to Light Main Flame 5.15.2 — Failure to Light Main Flame Shut off the main fuel supply and leave the gas pilot shutoff cock open. Turn the switch on. The pilot will light upon completion of the pre-purge period. The main fuel valves will be energized, but there should be no main flame.

  • Page 94: Maintenance Flow Chart Recommended Test Schedule

    Maintenance 5.17 — Maintenance Flow Chart Recommended Test Schedule Item Service By Remarks DAILY Gauges, Monitors, Indica- Operator Make Visual Inspection and record readings in log. tors Instrument and Equipment Operator Make visual check against recommended specifications. Settings Low Water, Fuel Cutoff and Operator Refer to instructions.

  • Page 95: Troubleshooting

    Troubleshooting CHAPTER 6 Warning Troubleshooting should be performed only by personnel who are familiar with the equipment and who have read and understood the contents of this manual. Failure to follow these instructions could result in serious personal injury or death. Warning Disconnect and lockout the main power supply in order to avoid the hazard of electrical shock.

  • Page 96: Emergency Shutdown

    Troubleshooting sequence to determine the stage at which performance deviates from normal. By following a set routine may possibly eliminate overlooking an obvious condition, often one that is relatively simple to correct. If an obvious condition is not apparent, check each continuity of each circuit with a voltmeter or test lamp. Each circuit can be checked and the fault isolated and corrected.

  • Page 97: Troubleshooting

    6.3 — Troubleshooting 6.3 — Troubleshooting Problem Possible Causes Burner Does Not Start 1. No voltage at the program relay power input terminals. a. Main disconnect switch open. b. Blown control circuit fuse. c. Loose or broken electrical connection. 2. Program relay safety switch requires resetting. 3.
  • Page 98 Troubleshooting Problem Possible Causes Pilot Flame, but No 1. Insufficient pilot flame. Main Flame 2. Gas fired unit: a. Manual gas cock closed. b. Main gas valve inoperative. c. Gas pressure regulator inoperative. 3. Oil fired unit: a. Oil supply cut off by obstruction, closed valve, or loss of suction. b.
  • Page 99 6.3 — Troubleshooting Problem Possible Causes Modulating Motor Does 1. Manual/automatic switch in wrong position. Not Operate 2. Linkage loose or jammed. 3. Motor does not drive to open or close during pre-purge or close on burner shut- down. a. Motor defective. b.

  • Page 101: Lnv Series Fgr System

    NOTE: Check all burner and FGR wiring before operating the unit. Turn all power off when working with any wiring. Power must be turned off at the disconnect to the boiler. Boiler operation and FGR adjustment must be done by a qualified Industrial Combustion service representative. 7.1 — Description The LNV burner is designed to guarantee low emissions of <30 ppm NO...
  • Page 102 LNV Series FGR System 7.2 — FGR Duct Sizing Ducting from the stack or boiler to the burner is done by others. Typical sizing for the FGR ducts is shown below. All FGR duct piping should be covered with a minimum of 2" of insulation. The following controls are used in the FGR duct for safe operation of the system.

  • Page 103: Fgr Shutoff Valve

    LNV Series FGR System 7.3 — FGR Shutoff Valve The FGR shutoff valve is located as close to the stack as possible. A modutrol motor with a 90º stroke opens and closes the FGR shutoff valve in 15 seconds. Proof of closure for the shutoff valve is provided by an auxiliary switch in the modutrol motor.
  • Page 104 LNV Series FGR System 7.4.1 — Low NOx Full Modulation Combination Gas-Oil Burner Adjustment LNV burners are equipped with an FGR valve to lower the NOx emissions. An adjustable cam is provided to adjust the FGR valve position throughout the firing range on gas. Follow the steps for gas from Section 4.4.12 with the following additions: Make sure the FGR valve is in the nearly closed position.
  • Page 105 LNV Series FGR System MODULATING MOTOR FGR CONTROL VALVE 656-10219-000 FIGURE 7-5. FGR Control Valve - High-Fire Position 7.5 — Air/FGR Damper Assembly The Air/FGR damper regulates the volume of combustion air. Position of the rotary damper blade is controlled by a modutrol motor. The damper blade in the low-fire position is normally approximately 1"...
  • Page 106 LNV Series FGR System FIGURE 7-6. Temperature Interlocks IC-SA-1511 (02/2014) V/LNV Series Manual...
  • Page 107 Warranty Policy Limited Warranty: The Company warrants that at the time of shipment, the equipment manufactured by it shall be merchantable, free from defects in material and workmanship and shall possess the characteristics represented in writing by the Company. The Company's warranty is conditioned upon the equipment being properly installed and maintained and operated within the equipment's capacity under normal load conditions with competent supervised operators.
  • Page 108 extensive warranty obligations of the Company to the Buyer for such parts than the Company's warranty adjustment covering part manufactured by the Company as set forth in this subparagraph (10.4). Expenses incurred by Buyer in replacing or repairing or returning the spare or replacement parts will not be reimbursed by the Company.
  • Page 109 Startup/Service Report The following information should be filled in by the service technician at startup or after any adjustment to the burner. A copy of the startup report MUST be forwarded to IC in order to validate the warranty of the burner. Burner Model _______________ Serial Number_______________ Startup Date_______________...

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