Document NK82OjyoDaL360B0XLqrzJBE

OIL BURNER INSTALLATION INSTRUCTIONS BURNER >( L ^ crq ' 13 `C- co i ift W H0SLER8 AMERICAN STANDARD PLUMBING & HEATING P.O. BOX 2003 NEV: BRUNSWICK, N.J. 08903 Part No. 30740 ( 4/72) GEN RAL INFORMATION This manual is to be used in conjunction with the appropriate PFA-3 boiler manual. The boiler should be assembled, tested, and the boiler controls installed before the burner is unpacked and serviced for installation. All electrical and oil lines should be run adjacent to the boiler-burner instal lation. It is important that the serviceman and installer have the following instruments available for proper testing, adjustments, and servicing the burner: CO2 Test Instrument Smoke Tester Draft Gauge (Inclined tube . 0 to 1.0 inch) Oil Pressure Gauge Oil Vacuum Gauge Multi-Meter Flame Mirror The turners covered by this book have been specifically designed and tested for uie boiler-burner units involved. At the rear of this manual are specific chans showing "Air Handling Data", "Burner Data", and various parts data. For oroper burner operation the dimensions shown should be strictly adhered to. AIR FOR COMBUSTION It is necessary to have sufficient outside air for combustion to be supplied at all tunes to the Boiler Room. A permanent opening or duct should be provided such that the boiler input will not exceed 5000 Btuh/square inch of free area. The air inlet opening should be located at a point where it cannot be covered with sno'-- or where it cannot be obstructed by any other means. Movable louvers should not be used. Never depend on-an open door that can be closed for the air inlet, or rely on cracks under doors or around loose windows. -2 - 07803 FUEL SYSTEM AllBu ners are furnished with two-stage fuel units. Two-pipe systems are recon nended. Refer to Fuel Unit Literature for proper vacuum, pipe sizes, etc. Suggested piping is illustrated below. FUEL-UNIT ABOVE TANK. TWO-PIPE SYSTEM FUEL-UNIT BELOW TANK, TWO-PIPE SYSTEM 2 (t / ***B*m*m n*\ from ' \ building opening Ati 'nt above now level Install in accordant with underwriters and le<ei regulations -3 - Nestle I Met Return lino 07804 PREPARATION OF BURNER FOR INSTALLATION ON BOILER 1. Insert proper nozzle. (See "Nozzle Data" in charts <rf this manual.) 2. Check nozzle settings as shown in this manual. 3. Check electrode settings as shown in this manual. 4. Be sure all parts and settings agree with those shown in this manual. 5. Set drawer assembly to middle position on side of housing.. 6. Burner is now ready for Installation on boiler mounting plats. ELECTRICAL POWER CONNECTION Check burner, this manual, and wiring diagrams for the proper power supply to be connected to burner and controls. Note that all burners are factory wired, eliminating field wiring as much as possible. BTART -UP AND FINAL ADJUSTMENTS 1. Make sure that flue damper in PFA-3 bailer is in fall open position. (To be adjusted later if required.) ' - 2. CAUTION Make sure there ie water In the boiler and that there is oil in die oil line to prevent burn-out of Fuel Unit. 3. Connect oil lines to burner. * 4. Connect electrical power wiring to burner and boiler controls. i 5. Set air adjustments an burner to half open position. (These adjustments are temporary and will probably have to be changed to achieve proper emote andCOg readings. .6 Turn on power to burner. 7. Set limit and operating controls to deaged settings. Burner should start. .8 Check smote characteristics immediately. Adjust air to get No. 2 smote or less. 9. Check oil pressure. Should be 100 P.8.L -4 - 07805 10. 'heck C02 reading (should be 12% 1 1%) 11. Iheck Out Operation of: Limit Control Operating Control Low Water Cut-Off Ignition Characteristics Burner Safety Circuit Re-check CO2 and Smoke Readings SERVICE TIPS The following information has been compiled to assist the installer and serviceman in locating and correcting service problems with our "L/C" series burners. These burners are equipped with 3450 r.p.m. motors and pumps, one-stage firing, and with flame retention. All of the models can be fired with draft or with pressure in the firebox. (See boiler installation manual for maximum allowable pressure in the firebox.) A fort 'd draft burner supplies all the air for combustion and can be fired in a boiler with natural draft, induced draft or with no draft. Pressure firing is a term used when there is pressure in the firebox during the burne r operation. The pressure is produced by the resistance through the boiler or furnace and the combustion air supplied by the burner. AIR FOR COMBUSTION If lacl of combustion air is suspected, close the door to the boiler or furnace room and operate the burner for at least 30 minutes. If the flame appears to become gassy and tends to snuff out. Insufficient combustion air is the cause and corrective measures must be taken to provide the proper amount of air. BLOWER WHEELS (FANS) - VIBRATION If undue vibration is detected in the burner, it could be caused by the blower wheel being nit of balance. Check to determine if any foreign matter has been draws into the bu i*ner and lodged in the blower wheel. If not, replace the blower wheel. Remove the m tor from die burner and run it without the blower wheel to determine if there is am undue vibration. Replace the motor if the operation is not smooth. When installing a new blower wheel in the burner, it is very Important that it be secured tightly to the motor shaft. -5 - 07806 The replacement blower wheel must be located on the motor shaft so that the set screws bear on the center of the flat on the 1/4 H. P. motors. Make sure that the set screws on blower wheels are securely tightened. There should be adequate clearance on both sides of the blower wheel in the housing. The blower wheels used in the burners are dynamically balanced for operation at 3150 r.p.m. and any replacement should be an exact duplicate of the original. DRAFT The burners are designed for firing against pressure in the firebox, but operate just as satisfactorily in a natural draft installation. It is important that the vent or chimney be located so as to be free of downdrafts. Forced draft burners can operate with back pressure in the boiler and flue pipe, but strong surges of down draft can cause the fire to become smoky and erratic. Aftr r a shut-down the heat in the combustion area could damage the burner if it is forced back through the burner by down-drafts. It may be necessary to increase the weight of the vent or chimney above the building and in some instances install a di'tch cap or similar appliance to prevent downdrafts. FUI L SYSTEM The turners can be installed with a single line if no lift from the oil tank is invc Ived. If a long single line is used, it should be large enough in diameter so t -.at the vacuum reading on the fuel unit is no more than 10 inches. If the oil i .ink is below the level of the burner, use a two-line system. If tv o or more burners are piped to a common suction line, each burner must have its >wn check valve. If tl ; pressure gauge on the fuel unit shows the 100 p.s.i, cannot be obtained, the fue! unit should be replaced. The quick cut-off pumps used should never be adjusted above 100 p.s.i. A p essure gauge and a vacuum gauge should be used if a fuel unit problem is susiected. If the pressure is excessive, such as 125# to 150#, check the flame bas< at the flame retention cup. Excessive pressure may cause the flame to lift awa / from the spinner. The pressure should be maintained at 100#. -6 - 07807 Rel r to the fuel unit manufacturers data for the proper vacuum for the ins* llatlon. If the vacuum reads higher than the calculated vacuum (see mai ifacturer's instructions) check for restrictions in the oil line, excessivi y long lines, closed tank valve, kinked copper tubing, plugged oil filter, fro> in oil line, undersized oil line, excessive oil lift or a restricting check or f otvalve. If the vacuum reads low, look for air leaks in the suction line, val\ ; fittings or fuel unit. On a gravity flow installation, no vacuum will be sho n on the gauge except where there are restrictions caused by a closed val- , plugged oil filter, kinked, undersized, or excessively long suction line. All estrictions must be eliminated and undersized or excessively long lines rep iced with lines of a greater diameter so that the vacuum reading will be no moi .i than 10 inches. A s ging sound in the fuel unit may indicate air in the suction line. Excessively higi vacuum can also cause noise in the fuel unit. Air in the suction line can can i delayed lighting. This condition will in time coat the photocell with carbon and afety shut-downs may result. If il s suspected that the oil is returning to the tank after shut-down, inspect for leal in the suction line and check valve. If the check valve is not seating properly and nere is a slight air leak in the suction line, the oil will flow back to the oil tanl On the next start up of the burner, there will be a delay in the oil delivery whi the pump is lifting the oil from the tank. Repair any air leaks and replace the iieck valve if necessary. IG1- riON PROBLEMS Har (rough) lighting can be caused by ignition problems. Check the transformer for ade late spark. Check for a spark by momentarily short circuiting the transformer acr -is the terminals by use of a screwdriver with an insulated handle. A 3/4" Ion; .park should be obtained. If there is no spark or if the spark was weak (less that L/2 inch), replace the transformer. Check the spark gap with the dimensions in t installation manual. Wit standard control systems the spark should appear immediately when the burner staj s. If a delay is detected, check the power supply to the burner. When a con tian of this type is susjjected, the best check is to have a voltage recorder con cted to the burner for a period of 48 hours. This will indicate any voltage dro during that period. Voltage drops are usually caused by undersized wiring or ale ; run from the burner to the source of power. If delayed ignition is not corrected, it c ild cause an explosion. -7 - 07808 Chi ; the drawer assembly for possible high voltage leaks in the insulators. If b loubt, change the electrode assemblies. Check the electrode springs and poii > for adequate clearant e to the ground. Check for carbon on the electrode poii s. Check all dimensions on the drawer assembly according to the dimensions sho' a in the manual and reset if necessary. If th cup is not correctly positioned in relation to the end cone hard lighting could occ . This is usually caused when the cup is positioned too far back inside the end one. To correct this < ondition, loosen the screw that locks the drawer assembly in p ee and move the assembly forward in steps of 1/16 of an inch until the lighting is s ooth. Be ire to tighten the set s< rew after making this adjustment and check the electrode spr gs from the electrodes to the transformer, making sure there is adequate cles ance to a ground and there is no possibility of a short circuit. If tl fire is clean with no smoke while in operation, but the heating unit continues to 1 ;ome coated with soot, check for short cycles on the burner. Short cycling will ventually cause hard lighting due to carbon on the spinner and nozzles. Under thee conditions the limit control on the heating unit should be set with a greater diff' ential. INS 1UMENTS In i 'St forced draft units i. is impossible to view the flame satisfactorily so ins' tments must be used t- properly adjust the flame. Do t attempt to obtain a b ;her percentage of CO2 than a clean fire will give. Kei ng the heating surfac-- rf thi unit clean is more important than securing a hig r percentage of CO.,, et the flame at no more than #2 on the Bacharach scale. NO ;LES Us< mly the nozzles recommended for they are of the proper type, capacity and spr angle, and these nozt !es should give the best performance in each burner and unil combination under nor nal conditions. Ho' 'er, because of the gr at variation in fuel oils in different localities, normal con- 'ions do not always ap, ly. Nozzles will not always deliver the gallons per hour or ' - spray angle with whi 1 they are marked, and in some instances nozzles other tha hose fumisued as oriv mal equipment could give better performance. -8 - 07809 The 1 izzles used should give smooth lighting and be able to produce a CO2 readi g of 10.5 to 12.5 percent with no more than a #2 smoke. Do nc attempt to install the nozzle through the end cone. It is impossible to get a ight joint between the nozzle and the adapter unless two wrenches are used. Remove the drawer assembly from the burner and then remove the cup b fore installing the nozzle. -9 - 07810 BURNER ADJUSTMENT SETTINGS Boiler Number Burner Model No. & Spec. No. "A" I. D. Of End Cone "B" Nozzle To Back of Cup "C" From Face of Cup To End Cone PFA-34 PFA-35 PFA-36 PFA-37 LC334-A3/1171 LC334-A/1172 LC534-A/1173 LC534-A/1173 3" 3-1/4" 3-9/16" 3-9/16" 1/4" 1/4" 1/4" 1/4" 3/16" to 1/4" * 1/16" to 1/4" 1/16" to 1/4" 1/16" to 1/4" * C'JP EXTENDS IN FRONT OF END CONE ON PFA-34 BOILERS Boiler Number Burner Model No. & Spec. No. "D" Burner Flange To End of Air Tube Electrode Settings "E" Back of Cup To Electrode Points ,rF" Centerline Nozzle up To Electrodes "G" Spark Gao PFA-34 PFA-35 PFA-36 PFA-37 LC334-A3/1171 LC334-A/1172 LC534-A/1173 LC534-A/1173 2" 2" 2" 2" 1/32" 1/32" 1/32" 1/32" i/4" 1/4" 1/4" 1/4" 1/8" 1/8" 1/8" 1/8" - 10 - 07811 AIR HANDLING DATA Boiler No. PFA-34 PFA-35 PFA-36 PFA-37 Bi rner No. & ipec.No. IBR Boiler Rating GPH LC 334-A3/1171 LC 334-A/1172 LC 534-A/1173 LC 534-A/1173 2.65 3.30 3.95 4.60 End Cone Data I. D. Part No. 3" 3-1/4" 3-9/16" 3-9/16" C51671 C61681 C51691 C51691 Cup Data O.D. Part No, 2-5/8" 2-5/8" 2-5/8" 2-5/8" A40752 A40752 A40752 A40752 Boiler No. Bu ner No. & Spec. No. PFA-34 PFA-35 PFA-36 PFA-37 LC 334-A3/1171 LC 334-A/1172 LC 534-A/1173 LC 534-A/1173 Stabilizer Ring Part No. A41181 _ A41181 A41181 A41181 Disc Data Nozzle Data Qty. Size Spray Q. D. Part No. Used G.P.H. Angle Type 2-1/4" S40904-3 2-1/4" S40904-3 2-1/4" S40904-3 2-1/4" S40904-3 1 1 1 1 2.50 3.25 4.00 4.50 70 45 45 ioV/ CO CO Boiler Number PFA-34 PFA-35 PFA-36 PFA-37 BURNER RATING CAPACITY CHART Burner No. & Spec. No. Gallons Per Hour Min. Max. LC334-A3 LC334-A LC534-A LC534-A 2.00 2.00 3.00 3.00 4.00 5.00 6.00 6.00 TRANSFORMER Allanson Mfg. Corp. - Niagara Falls, New York Manufacturer Burner Model Sunray Part No. Name Part No. LC334-A3 LC334-A LC534-A M51072 Allanson 452 Type Burner - 11 - 07812 TWO -STAGE FUE L UNITS FOR OIL BURNERS Sundstran Hydraulics - Rockford, Illinois Burner M >del Sunrav Part No. Manufacturer Name Part No. LC334-A3 LC334-A LC534-A P40072 Sundstrand H3BA200 Shaft DIA. FLAT 7/16" 1-3/16" MOTORS FOR OIL BURNERS Marathon Electric Mfg. Corp, Wausau, Wisconsin Burner Model LC334-A3 LC334-A LC534-A Sunray Part No. MFRS . Part No. H. P. Frame Voltage and Cvcles Type Shaft DIA. FLAT M40061 48S34S3B 1/4 48-6 split 115-60 phase 1/2" 1-3/8" American-Standard Boiler No. PFA-34 PFA-35 PFA-36 PFA-37 BURNER MOUNTINGS PARTS INFORMATION Burner Model No. And Spec. No. LC334-A3/1171 LC334-A/1172 LC534-A/1173 LC534-A/1173 Air Tube Part No. -- -- -- Welded Flange & Air Tube Assembly Part No. A51232-7-3 A51242-7-3-1/4 A51262-7-3-9/16 A51262-7-3-9/16 - 12 - 07813