Document wqwrnrnLkqm3JyyyQxNpZN4oD

FORCED DRAFT SCOTCH PACKAGE UNIT I f *O f iofoifNi-s CHAPTER J General Information PAGE A. Introduction .................................... 1 B. Approvals ond Requirements........... 1 C. Boiler - General Information........... 1 D. Burner - General Information........... 2 E. Controls - Generol Information ... 2 CHAPTER 2 Installation Procedure* A. Engineering ond Design.................. 9 B. Packaging ond Hondling Unit .... 9 C. Setting the Unit............................... 9 D. Venting the Unit ............................. 9 E. Providing Combustion Air................ 9 F. Altitude Corrections........................ 9 G. Electrical Supply............................. 10 H. Gas Supply............................ 10 I. Oil Supply....................................... 11 Selection of Oil ..................... 11 Oil Tank Location................. 11 Installing Oil Tonk.................. 11 PAG' Oil Piping ................................ Oil Piping Systems................... Boiler Mounted Oil Heaters .. Integrol Electric Oil Healert. . Electric Line Oil Heoters .... Tonk Oil Heoters..................... H 11 12 12 12 12 J. Steam and Wofer Supply................... 13 CHAPTER 3 Slarting Procedures A. General Instructions..................... . 21 B. Special Instructions - Controls . . . . 22 C. Speciol Instructions - Oil Firing . 23 D. Special Instructions - Gas Firing . 25 E. Special Instructions - Gas-Oil Firing ..................................... 27 F. Special Instructions - Boiler .... 27 CHAPTER 4 Maintenance Procedure* A. General Mointenence..................... 31 B. Dolly Maintenance........................... 32 C. Weekly Maintenance........................ 32 WljTW- l.llf/4A.^lfJ4U^t" J- ' AS 000074 - - --------- .... --------- ----------- FORCED DRAFT SCOTCH PACKAGE UNIT PAGE D. Monthly Mointenance...................... 32 E. Annuol Mointenance......................... 33 CHAPTER 5 PAGE Service Gos-Eleclric Igniter . . 40 Service Electric Oil Heater . . 40 Set Linkoges.............................. 40 B. Service Check List........................... 45 Service Procedures A. Adjustments and Repain ........ 35 Replace Water Gauge Glass . . 35 Apply Manhole ond Handhole Coven...................................... 35 Remove Bearings......................... 35 Reploce Bearings ...................... 36 Reploee Pump Gear................... 36 Replace Rotor........................... 36 Replace Primary Air Fan........... 36 Service Atomizing Cup........... 37 Adjust-Air Nozzle...................... 37 Service Stop-Drip Trap........... 37 Reploce Shaft Seal................... 37 Service Oil Pump...................... 38 Check Oil Pump Operation ... 38 Service Viscosity Valve........... 39 Reploce Hinge Seals................ 39 CHAPTER 6 Paris Procedures A. Ordering ReplacementParts ............ 49 B. Replacement Ports Inventory........... 49 C. Ports List............................................. Index........................................... 50 Identification........................... 51 Description................................ 52 CHAPTER 7 Manufacturers Data ......................... 65 fij000075 i*t: FORCED DRAFT SCOTCH PACKAGE UNIT GENERAL INFORMATION A. Introduction This monuol on Kewonee Forced Draft Scotch Pockoge units hoj been prepored for the pur pose of ossisting the operating, maintenance, service, ond installation personnel in the proper performance of their duties. The monuol information is, of necessity, general in nature ond subjisct to modificotionby consulting engineer s|secificotions, factory certified construction drowings, stole or local codes, utility ond insurance underwriters' requirements. If questions orise concerning your specific re quirements or if odditionol information is needed, please get in touch with your locol American-Stondard Industrial Division or Kewonee soles representative, or write direct to Americon-Stondord Industrial Division, Detroit 32, Michigan. B. Approvals and Requirements The Kewonee Forced Droft Scotch Package Units are listed by Underwriter's Laboratories, Inc. to bum oil not heavier fhon Commercial Stondard CS12-48 Grade No. 6 when the model number includes the letter "H", ond oil not heavier thon CS12-48 Grade No. 5 when the model number does not include the letter "H", olso to burn notural, mixed or manufactured gas forgos or combination gas-oil burners. Kewonee units meeting the requirements of Associated Factory Mutual Fire Insurance Companies, Foctory Insurance Association ond special State, local and utility codes are available on speciol order. All Kewonee Boilers ore built in accordance with the Americon Society of Mechanical Engineers Boiler Construction Code. This code covers the specifications of the materials used ond outlines the method of construction and the test procedure. LOW PRE5SUK 1. All units are hydrostoticolly tested to 60 pounds pressure. 2. The units ore inspected ond stomped by o properly authorized insurance inspec tor showing that the unit complies with the A.S.M.E. Low Pressure Heating Boil er Code. HIGH PRESSURE 1. All units are subjected too hydrostotic test of 1-1/2 times the maximum allow able working pressure. 2. The units are inspected ond stamped by o properly authorized insurance inspec tor showing that the unit complies with the A.S.M.E. Power Boiler Code. C. Boiler-General Information The Kewanee Forced Droft boiler is of the Scotch morine type, two-pass, horizontal fire tube, ASM construction, mounted on ``I" beom skid base. Steel jacket with mineral or glass fiber insulation and lifting loops i'i stondord equipment. Fire tubes ore rolled, not welded, ond equipped with spinner blades for more efficient heot tronsfer. Reor occess door and cast-iron front flue doors ore gasket sealed for pressure firing. ''.WWW. '* `"s 000070 TP Trr IWIW'i fOSCED D*AFT SCOTCH PACKAGE UNIT C. Boiler-Generol Informalion (Continued) Steam trim (safety velvet, gouge, woter column oisembly, low water cutoff ond feeder) or hot woter trim (relief valves, altitude gauge and thermometer and woter feeder), fuel burning equipment, and required boiler and fuel burn ing controls are mounted and piped ready for field connection to fuel, woter,electricity ond heat distribution systems. See Figure 1-1, Page 3 ond Figure 1-2, Page 4 for ratings, dota, ond dimensions of the high pressure.ond low pressure boiler units. D.Burner-General Informalion The Kewanee Forced Droft oil burner is of the horizontal rotary cup type in which oil is de livered into a high speed rotating cup. As a thin film of oil is spun from the rim of the atomizing cup it enters into a cone of high velocity primary air which directs the shape.of the flame pattern ond assists in preparing the oil particles for combustion. The Kewanee Forced Draft gos burner is of the multiple-jet ring type design in which gas is mixed with the secondary air in the burner throat before entering the combustion oreo. Primary oir is supplied by the primary oir fan which is an integrol part of the oil burner. Secondary air is supplied by the secondary air fan which has odequote capacity to supply all of the oir required for combustion under a positive combustion chomber pressure, thereby eliminating the need for a natural droft type stock. Fuel-air control is by meons of o moduloting motor which, in response to heat demand, op erates the gos or oil volume control valves ond the primary and seeondory oir dampen to main tain the proper air-fuel ratio over a wide firing range. See Figure 1-3, Poge 5 for ratings and dota of fuel burning equipment. E. Confrols-General Information Operating ond combustion safety controls are provided to turn the boiler on and off in re sponse to steom pressure, woter temperature, or water level; modulote firing rote in re sponse to heat demandj turn the boiler off, end require monual reset, in cose of an unsafe firing condition; progrom the burner and blower operation to provide pre-purge, proved pitot, monitored main flame, and post-purge sequences. Control combinations to sotisfy speciol local job requirements are available at additional charge. Although the Kewanee unit is considered "automatic" in its operation, the operator must become familiar with the function ond maintenance of the various controls, valves, instruments, etc., which offect the safety and efficiency of the unit operation. Carelessness ond laxity in testing and maintaining the vari ous controls can lead to high operating costs, boiler damage, and even danger to life ond property. Figures 1-4, Poge 6 ; 1*-5, Poge 7 ; ond 1-6, Poge 6 show the major items of control equipment for the operator's information ond guidonce in following the instructions in this manual. 2 0 0 0 0 77 f~*--! B J ratings nil Aum#r ..... ......ft. -- UNM filrtl** ............. M.H .....04. ... |t*. -!>.......................... kti vorvwt ................... ...... KCM. <f1t *' opoPr * ** M* w............. u IZ1vMMuu 1tu*7 Ml u41s7 32H il i\ SI 71 J3m24o0 214 715 1973 U 07.7 1704 IT U III 1JJ nil 4020 44703)00 10300 197)0 J4.t 41 J) 37.0 314 *1 0707 Ui III 114 94.7 UM 04It 4 --IT u !63 230 2s3Sm0M0S0 (717 <970 7t;to ms 1130 32000 4lo3 7t m <o 0M41.4I 30.1 9H190I U) 301ft ms ms 1uMn.I 0744 MO s*7 IT u ^nr 96 --Jr TT 1J6 ~nr < 071 93)0 37100 innitsoi 4/370 m0IS4S0t4IoS0 jit nr cr a IS7SI U10 1111007000 70371 7)0 77S7 :m 03(00 70790 04(70 9400 It.O 1014 171.4 70.0 940 mi 1)340 HIM HIM 140.7 J19)619.0) 7H1700U0100 HI 4 210(4907) 210U1. 7*71 1330 1101 n1(u90 727017.)) 2040 333.0 J3441|9; 3074 39)1 315 43/ 10000 IJSJO 11104 11710 71SII 74197 7H7. Owintt iwrfice tt trtt (B*i*ciHH) . ua 7-ISO II w. . ............. 4V<# AtUC ................................. . > "TT I1T4S10o0 li "14B40T0 ISOSO ~nr 1I7(040SO0 tl i} ~rsr 2109)10000 "ST 2mUMtt ~nr 777ISISSO0 h "ITT 379H900O0 23 "DT 33034U0O0 24 4SJ 4300540000 2( 4*J 4470310000 n 57T 0070930000 0014i)(U0000 30 37 tti (049090000 34 U (V10 u?a i dimensions. Inches j -- luiftHtr .... M -- *<( Uhl fc|ht . ... j Tthrt ftfrftlt ... n -nw** 1 . . ............ 4--<ftb t *Mt* ................ U-- tilt.......................................... T -UK CMA** ........ I --Dow t* l*Kt................................. CC --IfBftfc ........................................ U --tout** ............ ....... FF --Ivkt bIkumki IBM......................... II --1|. it Cl < <* 10 II 13 04 10 M 17 00 19 17710 1<(30S9 17110* 1((00&3* 194 71IK IS(4* 20131 1n71 fit 730 I1I7H l72 2391040* I7f1f 7(7* 77$IS34 K ;i 201* 70N9)430H 78199M070t3K 221194M00f029t 04 I4S7HH 19 0140* wvs 90 979110* 94 979110* 100 917779* IITSt 11070I27K* 127* 110702I7K* 120* 11100210 132 i1n)3k n 11912491** 1*4 ISO* 31941710 43 Js7i a 431041)) S110470) 99Sm137 S(407I U 1741 (S4I I(S4 SI w is n u (ft u04 U u 1172 u17 13 n 13 Q 14 1709 10 a I7I9 3114 3177 4 IK I 4 IK J < m > ft I7K i 2IK 1 2IK i 2IK* i IK IK 1 IK IK t2 IK J7K i7t4* 1(13101101 J7H }<K II 1K141)1 IS* ISK 10174f0101t I7S1K 1012170099 4) 2S1IK 17711711* a 410234H 71 I'K ITS 77tK 4374H a 7M7JI1177KK 4) a a 0147 IKK II a K a 9117070 a 4344K 91f1t H1I0M ISK U 13 M37 S'H 91 13 32 i3<7 >17 in m 171 1ST IM 151 34 >s an 33 K 7n391** SSK IS U MK I4S4 2S9S m 234fItK 90 91 2m11140011212 771110111*70024 111207007** I11730S74V**S 131* 117 1(1740 Ift l_0t4t a71 4110 1(29 221* a2* ?* ISK a34 s90o a 91f1t 90 It o1i2k a17K ISK an 1(1 its 2a4 374< a* a* 92 7I710SK 7l5l(4 no 1113303(7* IM 14774719 TO 1220** SI 3i9i 90 23I13421t 1(7 320i a 9) 307 W170H m1)4 11131*070** 1H 0747 n 21 1720H* 0072 *( 102 2a4n107** >17 a7* a *rw mu! mMi rutfabMi Is man Wo. nlit W Ktwum 'im Dili. HI*L FIS. |.|--HIGH PRESSURE BOILER DATA &M5S Wy - *: AV- fiS 00007S tllirif--........................ .................... ................_ ............................... -- itttfll p* imt 217*7................................ s. ................................ *** _.m......................... .. ** MCA Ml Uim ......................... *1 f*11*1 nU--d 1*000 III......................... IP*- -Ml DOOM IK...................... I* -t ................... WUrt- HllliAf wrtK# AJML.................................. ** J* Nil tufNICt ICKNft.............................. "I ' iilm rwt UIK.IJ It IIIIM M> " 10 1) TUI 2110 nuo 19(10 IU0 730 2)4 1503 41? 123 liii tl 1 3231 3330 13340 71730 10000 211 VJ 1074 MS 31.1 USJ li Jll mi 40*0 itrto 7090 121(0 333 330 49U 41* US jiii u 139 *437 1710 19*00 31030 IOOO 41.1 311 3121 1*3 933 *UJ w IS l( t?3 3120 3*10 24730 34100 7C4 (M2 7170 29090 i(S30 2(2 IUI 1340 33910 3*230 DIM 320 413 7274 21**0 (23 312 1721 :wco tm CM 111 >1 J(4 1039 1211 1121 137.4 132.4 3120 ruir JIU "IT u it 2/7 9300 9330 34730 (2000 11(19 II *30 44410 774(0 413 13*37 1*310 31070 *2970 24340 U.O 77.3 11(2( 1S3I0 IUI Ml 14S14 litu INI till 17477 1344 I7 2074 142.0 III 272 1 JOO imr utjj 90 *1 1(234 14490 47730 101370 333 ts;4 19070 77390 173130 mi ms 71)170 111*0 list IS4I mil 2419 27(4 334.0 334 2 1(234 , 113/4 97 (22 70444 21*30 17070 1397*0 41 NO IIU IN.I 7H07 31C4 3*11 70114 *3 (91 23711 2 3430 14710 1347*0 IU74 707.2 1*3.4 29014 3*34 *33 X aaia Ovliid* imUti i eetf (vAiKMirt) VtAl .................... M.K *. ML "nr -nr 10230 13 HIM14 ~nr tl1a7 -nr "15T lilSO 19 Tfsw" 20 sr 20300 72 "JT 72730 73 *10 2(400 7* 470 joiio 24 "55" 3S900 24 --ITT 40700 30 ni 43(00 12 (SO 4720340 494 30630 34 dimensions. Inches A --nap* mull............................... 1 --dtA mA ..................................................... 6 --itAfW.................................................. ( -- 4unitt* ................... C --tffwht MM tofftt.......................................... i --uUfJ W*m Mt|M....................... 4 --*1rm MOP*?....................................................... 1 -- uft* **....................................................... M -- f*rtf !*--Kfc u4........................................ M -uiyit-ua MM .......................................... f --ijf*.............................................. 0 -iriMU MlM-iwdt rttl.............................. S -> M tar WM*r M................................ T to* ...................................... U ^4ni tot...... ....................................................... y ttfaH.................................................. W -lnfftMt-CtfAt................................................. X --*tffa OiMwtff................................... t --4441 tUw>N>............................... AA-U*-ffU......................................................... It --floor t talar................... ...................... CC --...................................................... (t --taut**............................. ff --lata fifUctmtn* tpae*...................................... /J --iia it Cl a* t(4 79 II IS 40 u ovt 44H ft 37 O 24 43 u 17 9 4 2 m )m 29H 24 ii IS i 9 1% u 11 J7 f] 11214 79 44 1*(H 10 (4 ISH 44H U 43 ?0 33 H 43 41 12 17 1 4 2 IX 1/H 29H 24 40 19 1*3 1 17H M 13 24 37 12 113 (*H (9 1*4 44 90 91 TO* tsst 44 (9 341? 11 1) 22 1 1 2 m ji SH 24 44 11 1*4 1 10 94 a 74 >7 u 70SH M 19 1UH 44 91 NH 93H 30 94 41 7H *IH 13 22 * 4 2 1H 39 22H 21 u II 147 1 I0H 114 J4 71 an 14 IS 2I7H n 73 111 H 72 21IX 94 1) II1H 71 tr 102 7H 102 74H 77H icon 37 44 4) SIH *IH 103H 31 44 1) S0H *4H 14 13 n 21 t1 44 22 IX !H 41 47 )*H 3/H 21 n 72 M* 179 1 I0H 71 I7H 171 I H i2<n III ua 71 71 1IH H u 17 2*)H *7H 1) 2QSH 71 743H 100H 17 704 (4 Ml in 77H 107 tom I07H a ID 44 * 49 34H 44H IS 94 43 U 99 13 14 29 1 1 ?H 1H 42 )7H 74 71 I7H 704 1 *H 1 4 2H IX <3 41 S 14 17 19*H 10 21 147H IS U >m 71 44 44 It 7S4H no 93 770H tux 11) I7H lit IS n 49 70X SIH 11 3* 10 1* 2H m 44 VI 4JH a 17 W 10 73H ISIH 33 23 4| 19 7H ni 99 2SX 94 I21X U9X tt 124 44 in 3) NX MX 17 )7 to $ 7X 2 *7X 4IH 34 94 It 777X 10 72 139 H 74 UH 90 274 17? 103 734 102 I77H 111V1 MH 132 17 104 SI 74 11 19 40 10 4* 2H 2 !H UH 14 94 It 222X 17 7X 141 IS 24 ax *i 7SI 17S 109 2*4 104 131 129 102 USX 44 101 30 U (4 19 42 ii 4* IVf m MH UH M M 11 771H 11 11H 147 M N UH *7 7UH mx m 2sox no 133 131 10$ U9H n 10i 4*H 10 71 79 44 17 4* 7X 7X 32 MH 34 91 11 730H 12 SI 14) 33 21 34 U 794 1M 117 l III 139 137 in 1*3H 72 104 49 94 72 21 47 U 4* 7H JH U MH 42 107 It 7SH 12 SX IHX M 24 SI |JQ |b AmefCJ SUtftr Djam **f* i*w**i wort iMikf 0ti(**l*Aft tr vinovt fvrfi. nft t Im'AW DU. Hi* i FIG. 1-2--LOW PRESSURE BOILER DATA 4 AT 000079 *. >- : 7S-' ( FORCED DRAFT SCOTCH PACICAGE UNIT Ovj kkA 4Hk --" "O j *. X0 J = fs 0 *, IVs 1 *55 z* i EJ ?SSBBBSSSC?3^ sssrrsssssg|? ---nnnnnnnn S8r.n3nn3m~irt>rtAXPrtV(^ >>^>eooeooo^>*Ap% ^>op^r<nnniOKKNA OOOIAIA<AOOOOOO<A<A 1u! u j . D -S V > Pi Ui *1$ ill * > i{ ~ 4 ?S *3 jc j ; *dJ sss 2s ss Art<A>^PvKK^ *OAjjO SS ss ll n ".i J 06666666606000 i S* % >i s-s 2=2213428*25/? ~I 1 1 1 1m m iii 7 TTT m mUU WkMWk^k^t^fkiA<kAViA<kAk<Ak<kA<kAK>> s 51 J 1 1O z MO* 0 # i1 O - N A < AKkp-*A|"*A ?Vi**iW**xk*?Wm*tV*?***Tx**7kA*iTaxA*?A*Tx*A*k:*A1:*Ax^>*z> * o> i =4 O( 1 2 0 . n<Z iiJ1* '1-& ito& 0-NA<A4KBkP*7^t 7uAk*M7*ulWA7*uWA7*uW7A*uW7*AuW7*kuI7*WAu7*Wku7*WAu7*IMku7*'kMu6*/P?-*6^j v " I. I Bio 4 0O* AA A 4K ^ ^ nn T 7 7 7 7 7 71 7 7 7 7 j; j A**A*A*k*k*A*4*k*kk*A*l*k*7*> FIG. 1-3-- BURNER DATA J" 0 0 0 0 8 0 m Ij r p !*.;!11 MFIG. -- BOILER IDENTIFICATION FORCED DRAFT SCOTCH PACKAGE UNIT' GAS VOLUME CONTROL VALVE I t-3 oaoI-. o z p< oQ s J "W* 7 /U-000082 ,.y*ia EO*CED DdAFT SCOTCH PACKAGE UNIT |- - - - MANUAL HOLDER WIRING TROUGH [^PROGRAMMING CONTROL FIG. 1*6 CONTROL CABINET IDENTIFICATION k-jp. fOPCED D8AFT SCOTCH PACKAGE UNIT G. Electrical Supply The Kewonee Forced Draft Pockoge hos been foctory prewired except for three possible conned ions: (1) source of power, (2) remote oil pump, (3) remote emergency switch. See Figure 3-1, Poge 28 for a schemotie wiring diogrom of the controls ond motors. The wiring diogrom for your particular unit is fostened inside the door of the control cobinet. Wiring connections to the Kewonee unit shall be installed in con^liance with the rules of the Nalionol Electrical Code or ony locol or other codes hoving jurisdiction. All motors ond electric healers on the unit are protected by fuse blocks inside the control cobinet. Wiring from the control cabinet to a remotelocated oil pump or emergency switch shall not be less than No. 14 gouge wire. The normol size of wiring to the boiler control cobinet ond main panel fuse size ore shown below: - Boiler Size 80-82 83-85 86-87 88-89 90-91 92-93 TYPICAL WIRE AND FUSE SIZES Oil ond Gas-Oil Models Gos Only Models Wire Size Fuse Size-Amps Wire Size '10 30 '12 ' 8 50 '12 ' 8 60 '10 ' 6 100 '10 ' 6 100 '10 ' 4 100 '10 For 230 Volt, 60 Cycle, 3 Phose Operation Fuse Size-Amps 15 15 20 - 40 50 50 H. Go* Supply The gas piping ond gos control sizes furnished os standard equipment with the Kewonee Unit, ond the minimum gas pressures required ot the manual gas cock ore shown in Figure 1-3, Poge 5. These control sizes are based on notural gas. Special control groups for LP gas or manufactured gas are availoble on special order. Gas control groups for higher or lower pressure than that specified in Figure 1-3 are available on special order. Gos pressure regulators for the main burner ond for the gos-electric ignition ore included os part of the stondard boiler equipment on jobs using notural gas. No regulator is sup plied for LP gos. A source of constant gas supply is required for the gos-electric ignition on both gas ond oil firing. Gos piping should be sized to provide the re quired minimum pressure at the monual gas cock when operating at maximum input. Con sult your locol utility on ony questions re garding gas pressure, piping pressure drops ollowoble ond local piping requirements. Gas piping should be instolled in accordance with the National Board of Fire Underwriters' Pamphlet 54 ond ony other local codes which may apply. All gos piping should be tested offer instollotion with oir pressure or inert gas of at least three times the gos pressure that will be used. The piping ahead of the monuol 10 4J- 000084 ( V \ r/l***KS-^l'Wl*rUS*irU '* , / -J <i rf.jj.-----w'.fv* ^vacw <*.?---.-^'X-.frr-ra-n; szEjar-z^ssa; FORCED DRAFT SCOTCH PACKAGE UNIT y- `l<k77,-',- .r . H. Go* Supply (Continued) shut-off volve sholl include o full size dirt pocket or trap. The stondord Kewonee gas control group is in occordonce with the requirements of Under writers* Laboratories. Special control groups meeting the requirements of Associated Factory Mutual Fire Insurance Companies ond the Fac tory Insurance Association ore available ot odded cost.. Loco! code and utility companies moy require special ond additional gas con trols. The gat control arrangements required by various insurance underwriter* ore illus trated in Figure 2-1, Poge 14. I. Oil Supply SELECTION OF Oil; Fuel oils normolly used in the Kewonee Forced Droft Package Unit ore Nos. 2, 4, 5 ond 6 or Bunker C. No. 2 ond No. 4 oils ore normolly burned without ony preheating equipment. Becouse of wide variation in viscosity and pour point, some No. 5 oils con be burned with no heotlng, some with only burner electric heating, and some No. 5 oils must have com plete heoting similar to No. 6 oil. No. 6 is generally more attractive from a fuel cost standpoint, but cost of oil heoting equipment, maintenance cost, local ovoilobility, use of oil as stondby fuel to gas, and other factors must be considered before selecting the fuel to be burned on any installation. OIL TANK LOCATION: The rules of the Notional Board of Fire Under writer* (Pomphlet 31) and of Stote and city regulations, if any, should be followed in lo cating and installing oil storage tanks. The oil burner will operate satisfactorily with the lank above or below the burner level. When the tonk is above the burner level the return line pressure should not exceed 15psi. When the tank is below the burner level the bottom of the tank should not be more than 15 feet below the level of the burner pump or of the high point of the suction line. Tan higher or lower than those above con be us< with auxiliary equipment. Consult the loc Kewonee soles office in such cases. INSTALLIN'; OIL TANK: Consult local authorities for specifications < installing inside tanks. Outside underground tanks should be buri with on earth cover or by o combino-tion eorth and concrete. Before starting to e covote, it is odvisoble to check the locoti of sewer, water, ond gas moins entering t building. Tanks buried in soft earth or in high moisture orea moy require anchoring w' steel straps to o reinforced concrete mot unc the tank. Fill pipe and vent line shall be installed the tonk in accordance with local ondnotior code requirements. See Figure 2-2, Poge fora typical oil storoge tonk installation. OIL PiPINO: Suction piping should be tested to the bott of the tonk. A vocuum test holding 25" vacuum for a period of 12 hours is the sof suction piping test. No gate valve sholl be installed in the retu line without a relief by-poss. The normal oil pipe sizes for a moximum of equivalent feet of length ond 12 feet of ver cal lift ore: 2" suction ond return on Ur 80-85; 2-1/2" suction ond return on Ur 86-88; ond.3"- suction and return on Ur 89-93. These pipe sizei apply to No. 5o No. 6 oil. For light oil pipe sizes end mi tiple installations, consult your loco! Kewon sales office. OIL rtFINO SYSTEMS) The Kewonee Forced Draft Scotch Pockoge equipped with an integral oil pump on ur eefHbU^f?Mi: ,ntnaar fOftCfO DRAFT SCOTCH PACKAGE UNIT r" I. Oil Supply (Continued) burning No. 5 and lighter oil. Figure 2-3, Page 16 illustrates the arrangements for inte gral pump burner* using the lighter grades of No. 5 fuel oil. High pour point No.5 oili will alio require tank oil heoten. See Figure 2-2, Page IS and Figure 2-6, Page 19. Separate suction lines or on ouxiliory pump set should be used for multiple installations. The piping layout in Figure 2-4, Poge 17 shows o circwloting loop system with o seporofe pump set supplying oil to integral pump burners. Any number of bailers may be connected to the loop os long os the separate pump set hos sufficient capacity. Note thot oil burner sup ply lines ore token from the bottom of the loop in order to reduce the chances of air being drown into the burner. The Oil Flow Diogram in Figure 2-5, Page 18 illustrates the arrangement for o Kewanee unit designed to burn No. 6 Bunker C Oils. The oil to the burner is supplied by o separate pump set, furnished with the boiler unit, which may be mounted on the boiler skids or at o re mote location neor the oil tank. This system oiso includes an integral electric oil heater on the burner, a hot oil well or tonk coils in stalled in the oil tonk, and a steam or hot water oil heater mounted on the boiler. BOILER MOUNTED Oil HEATERS* A below-water-line oil heater (on hot water or low pressure steam units) or a steam oil heater (on high pressure steam units) is sup plied as a component part of the Kewanee unit for No. 6 oil. Stondord oil heaters are of the boffled U-tube type. Safety type heoters, as required in many local areas, are available on tpeeiol order. INTEGRAL ELECTRIC OIL HIATUS; Integral electric oil heoters are mounted on the burner to ossist the auxiliary oil healing equipment In maintaining oil temperature at the atomizing cup, and also to assist In tlarl up after a burner shutdown. For further in formation regarding the electric preheater tee the Service Section of this manual, Poge 40. Stondord wottoges of heaters ore shown on Figure 1-3, Page 5 . ELECTRIC LINE OIL HEATERS: Most systems of oil healing involving electric line oil heaters, such os the "Thermo! Elec tric" system, are designed and supervised by the manufacturer of the system. The contrac tor installing the boiler should check to make sure that the oil piping requirements (or the Kewanee unit have been met when using this system. TANK OIL HEATERS; All No. 6 and heavy No. 5 fuel oil Installa tions should contain a provision for heoting the oil in the tonk to o pumpable temperature. (3,000 S5U maximum pumping viscosity.) A tonk coil or suction bell heoter may be used to heat the oil in the vicinity of the tank suc tion line. Either steam or forced hot water may be used as a heating medium for the coil. This type tonk heoter, combined with the inte gral electric heater, is normally used on high pour point oil. For No. 6 oil the boiler mounted oil heater is also required. A hot oil well may be incorporated in the oil piping tyttem when o boiler mounted oil healer is used. This system permits the return of hot oil to the vicinity of the suction line. Hot woter or steam lines may be inserted through the well to extend full length of the tank in case of high pour point or mixed oils. See Figure 2-2, Poge 15 , end Figure 2-6, Poge 19. Steam or hot water lines supplying heat to the tonk coil should be insulated and waterproofed with the oil suction ond return lines. See Fig ure 2-2, Page 15. When a high pour point oil, such os No. 6 or Bunker C is used as fuel, the oil pump should be set for constant circulation of oil between the tank and the burner. 12 000086 /bS FORCED DRAFT SCOTCH PACKAGE UNIT J. Steam & Water Supply The Kcwonee Forced Draft Scotch Pockage in cludes woter column, gouge gloss, gouges, thermometers, safety volves, low woter cutoff, blowdown volves, water feeder or feedwater pump switch mounted ond piped. Inspect these boiler mounted accessories carefully to make sure thot no domoge has resulted in shipment or installation.' Feedwoter openings with baffle plates are lo cated on each side of the shell. See Figure 1-4, Poge 6. Do not feed woter through the drain, opening at the bottom of the shell. Check city water pressure and install pressure reducing valve if necessary for proper opera tion of the woter feeder on the low pressure boiler. Do not permit a boiler filled with row water to slond idle over on extended period of time. Feedwoter treatment varies considerably ond depends on the pressure ol which the boiler is operated, the row woter source, the per cent of make-up woter required, ond other factors. Feedwoter treatment should be used because it prolongs the boiler life end helps produce o better quolily of steam. A certified woter consultant or woter treating company should be contacted ond their recommendations fol lowed rigidly. Risers ond returns should be piped according to Job specifications. In the obsence of such specifications,consult the loco! Kewonee soles office. All boiler drains, blow down volves, safety volves, woter column blow down, and low water cutoff blow down should be vented to o convenient sewer, or to a blow down tank on high pressure steom. ( I'WUliU-6 .-JIHP'.H. JUI' L i 13 AS 00008T 'Wt FORCED DRAFT SCOTCH PACKAGE UNIT gsijj|pis$ #5 00008^ UNDERWRITERS REQUIREMENTS. fOKCED DRAFT SCOTCH PACKAGE UNIT 17 000091 II " ' 1 * 11 FORCED DRAFT SCOTCH PACKAGE UNIT 1$ JET* S3 SWING MANIFOLD FIG. 2-5-TYPICAL OIL FLOW 18 A5 000092 Wf fORCED ORAPT SCOTCH PACKAGE UNIT iilF 5r}cax-$tandard;$* * C-I-53 f*5 C^n^grryn L--as^ -aiy,i-iTr*>cy^TT?n^ ___n__iv_r_rr_ seasaa3uaessE!SL2SBs FORCED DRAFT SCOTCH PACKAGE UNIT 5. Special fnjIruclionJ-Confroi* I. The Kewcnee Forced Draft Package uses the Mirsneopolis-Honeywell R-478B, or fireye FP-2 system, to control burner op eration and combustion safety. Before attempting to operate this unit the boiler operator should study eorefully the con trol instruction sheets in Chapter 7, Man ufacturers Dota Section. 2. The operator should become familiar with the location and purpose of all controls governing the boiler's operation. Sche matic wiring diogrom. Figure 3-1, Page 28, Figure 1-4, Poge 6, Figure 1-5, Poge 7, and Figure 1-6, Page 8, show the most important valves, instruments ond electrical controls which regulate the boiler operation. 3. Sequence of operations. The following description is based on Figure 3-1, Page 28, ond Figure 3-2, Poge 29 which shows o, Minneopolis-Honeywell R-478B flame safeguard system. Refer to wiring diogrem ond sequence of operations in con trol cabinet of eoch unit for specific re quirements: Requirements for burner storting: Cold oil lock out (No. 6 oil only), latch switch (36), burner control switch (18), remote emergency switch (47) (if any), low water cut off (48), operating pressure controller or oquastot (50), high limit pressure controller or oquestot (49), low-flrestart switch (40) ond ges volve auxiliary switch (51) must be closed. Alt the above switches, except the operating limit control (50), should be closed after o normal burner shut down. When the operating limit control (50) colls for heat, reloy (12) will commence the prepurge period by energizing blower motor (31) ond burner motor (32). After o 30 second prepurge period, the ignition transformer (43), gas valve (44) ond ignition indicoting light (13) will be energized and pilot will be established. In an additional 10 seconds, providing pilot flome It monitored by scanner (41) ond oir switch (35) is actuated by blower air pressure, main fuel volve (38 oil) or (51 gos) ond moin fuel indicoting light (14) will be energized. The moduloring motor (39) will start to high ' fire position depending on demand of modu loring control (46). If monuol-oulomatic switch (22) is In manual position, potentiometer (23). sett fixed firing rote with no modulation. If switch (22) is in automatic position, potentio meter (23) sets maximum firing rote with modu lating control of lower firing rotes. In on additional 60 seconds (oil) or 15 seconds (gos) the ignition tronsformer (43), pilot gos valve (44) and pilot Indicating light (13) wilt be de-energized. Now the main flome is monitored by scanner (41). When operating controller (50) is sotisfied or ony of switches (18), (36), (47), (48) ond (49) ore open the main fuel volve (38 oil) or (51 gos) and moin fuel indicating light (14) are de energized. Modulating motor (39) will return to low fire position, bjower motor (31) end burner motor (32) will continue to operate for a 15 second post purge period. Ignition Foilure: If pilot is not ignited or scanner (41) does not properly monitor pilot, main fuel valve (38 oil) or (51 gos) will not open and warp switch on relay (12) will be energized. The unit will go info Nome foilure position and energize flome failure indicating light (15). Flome Foiiurc: Following o normal cycle -- pilot on, moin burner on,-pilot off--If the moin flome is extinguished or not properly monitored by the scanner (41), the moin fuel valve (38 oil) or (51 gos) will close in approx imately 4 seconds and modulating motor (39) will sforr to low fire position. The safety worp switch is energized causing the burner to go to flome foilure position os shown by indicoting light (15). 22 4S 0 0 0 0 9 5 ( T MBfucAX-^andani .i tj. ^ zsr.. -=iiJ`jL^r^^L r.-jrr^^ >.iw3MLw^r^i-sjc:?r c:<asi^j^f&5X!J:Cr" FORCED DRAFT SCOTCH PACKAGE UNIT, B. Special Jnsfruefioni-ConlroJs (Continued) Air Switch foilure: In cow the forced draft blower does not operate, or If the oir Twitch (35) fails, the burner will go through a normal pre-purge ond ignition cycle. The main fuel voive (38 oil) or (51 gas) will not open ond the burner will go to flame failure posilion shown by indicating light (15). Whenever the burner goes into the flame fail ure position, light (15) Is on. Wait three min utes to ollow warp switch to cool, then manu ally re-set reloy (12) to re-start burner. NOTE: Selector switch (20) permits selection of fuel (gas or oil). Electric oil heater (33) is not energized when gas is selected. Pump switch (21) permits manual (constant) or auto matic (operotes with burner)oil pump operation. C. Special Inslrvclions-Oil Firing 1. Be certain all oil and gas piping is com plete and necessary valves are open. 2. Purge the air from the gas line leading to the gos-elecfric ignition assembly. Open shut-off cock to gos-electric igniter. 3. Disconnect power to the electric oil heofer by either removing fuses in the control cabinet or disconnecting one wire at the temperoture controller mounted on the oil heater. 4. Check oil burner linkoge. This linkage was set by the factory when the boiler wos fire-tested, but the following settings should be checked to determine whether damage has occurred which disrupted the linkoge. The primary air damper should be about one-fourth open. Secondary oir dampers should be about one-fourth open and the modulating oil valve should be cbout one-fourth open. Slots in the end of the shafts controlling the airdompersond the modulating oil valve indicate the throt tling position. 5. Close the gate valve on the burner cared upstreom from the oil soler voive. 6. Remove cop from oil strainer In suet line ond fill strainer with fuel oil or bricoting oil. After the burner motor been storied, refill the strainer as re^ui to provide sufficient oil to prime pump. When replacing the oil strai cop be very careful to assure o vocui tight seol. 7. Operote the oil pump until oil is obloi: from the tonk. With a separate pump : the oil pump may be operated by leov the burner switch in on "off" posit and turning the oil pump switch tc "monual" position. On on integral pi burner, the oil may be pumped by tu ing the burner switch to the "c position and removing the fop voci tube from the R--476B relay. If prefers the-oil pump may be operated by m< uotly holding in the coil on the I starter. 8. Observe the pressure gauge when the is pumped to the burner. Pressure sho not exceed 20 psi. Higher pressures, w a separate pump set, are generally ecuby o closed or partially closed valve the pressure side of the pump. Higpressures, on an integral pump, may reduced by closing the oil viscosity vo slightly. 9. Turn off the integral pump by turning : burner switch to the "off" positi' The separate oil pump may be left "manual" or switched to "outomoti on the pump switch. 10, Check spark gap on gas-electric igni (1/16"-3/32"). Noturol ond manufactur gas pilots hove o 3/16" orifice . 1 LP gos orifice is 7/64". 11. Remove top vocuum tube in the R-47 and push tab on top relay. T'r will provide a constant pilot duri 23 frj 000096 J2i T&gagH&i&asits&gi gr.y-.ag- FORCED DRAFT SCOTCH PACKAGE UNIT C. Spatial Jnifrvcliotu-Oil Firing (Continued) the storting operation. On the Fireye FP-2 control a constant pilot ti secured by replocing the four-pronged AC line plug with a three-pronged test plug, ond turning the knurled knob on the timer to the desired phose of operating sequence. 17. Bring the unit to high fire by turning the manual potentiometer to the "open" po sition. Be sure gate valve Is wide open. Increase or decrease the high fire oil rate by opening or closing the viscosity valve, if adjustments are required. 12. The pilot flame should be carefully cheeked for proper operation. A reoding of 100 to 140 DC volts should be indi cated from the test jocks on the R-478E control. A reoding of between 70 ond 90 DC volts should be indicated on the Fireye control. The gos pilot normally requires 2''-4" w..e. pressure fornotvral or manufactured gos. Check gas pressure at Tee outside the Igniter assembly. Adjust the pilot gas pressure regulotor as necessary to secure a goodstable pilot flame with no fluctuation in voltoge reodings. 13. To light off the oil burner, set the manual potentiometer in o "closed" position. Set fuel selector switch on "oil". Turn on the burner switch. The burner will go through its pre-purge period, the pilot will turn on ond be proved, permitting the oil solenoid valve to open. At this time, slowly open the closed gate volve on the burner. After a slight deloy oil will be delivered to the cup ond the main flome will be established. If oil is not delivered to the cup within o few minutes, turn the mcnual potentiometer up so that the mod ulating valve will open further. Reconnect the electric heater after a flame is established. 15. As soon as o stable flome is established, hold the fire ?n this position by means of the manual potentiometer for a period of about 30 minutes or until the water in the boiler is warm. 16. Adjust oil femperoture control on the electric oil heater to femperoture re quired to provide atomization of oil. These temperatures may vary from 100 to 140 for No. 5 oil and from 130 to 200 for No. 6 oil. 18. Unit should be operated at high fire until steam pressure or boiler water femperoture is high enough to enable any auxiliary oil healing equipment to provide o stoble source of heat. The burner should remain on constant ignition during this lime until oil of the air pockets In the oil line hove been eliminated and oil' temperatures through all heaters are constont. 19. Chonge the burner firing rote from high to low several times by means of the monuol potentiometer. Check CO2 of high, low ond intermediate fire. The Kewanee unit should not require any major firing ad justments since it has been factory fired and tested. If minor linkoge corrections are necessary, see the Service section of this monuol. Page 40. Adjust fuel-air ratio to oehieve 11 to 12-1/2 C02 by flue gos onolysiswith o smoke rating of notin excess of No. 2 on the Shell-Bochroch smoke scole. 20. Restorf burner several times to check for smooth light off. 21. Flome failure cheek; a. Replace vacuum tube (Tl) in the R-478B reloy. b. Start burner. c. After the ignition indicating light goes off, close the manual fuel valve* on the burner rapidly to extinguish the main flame. d. In approximately four seconds the automatic fuel valve will close and the modulating motor will start to a closed position. e. The R-478B relay will go to lockout position and the flame failure light will show on the control cabinet. 24 #5 0 0 0 0 07 -'S'** ;-' \ ^-^--7*;"JT-i*. ^- -V \r ^hi1 rlfMi^i trzS^^r/i^ 9Vr.X/(Jr/* r*mfa*lgTfrrTrTT7TI~Jrf-'irir-r^-1r"Vrr*rfa>^*w< FORCED DRAFT SCOTCH PACKAGE UNIT, i. / I < 4I ^ i\ ,.\. :V--y ,; T1 C. Special Initrvctions-Oil Firing (Continued) 22. Ignition foilure check: o. Close the shut-off cock on the gas pi lot line. Jumper pilot low pressure go* switch (if ony). b. Stort the burner. c. The ignition indicating light on the control cobinet will come on but the pilot flame will not be established. d. The moin fuel valve will not be ener gized. e. The pilot indicating light will go off ond the unit will go to o flame foilure position. 23. Limit control check: a. Stort the burner and permit the boiler to run until the limit control settings as shown on the limit controls hove been reached. b. The burner will turn off when the set pressure or temperature has been reached. Occasionally there will be o slight difference between the set tings on the limit controls and the readings on the pressure or tempera ture gouges. The limit controls should be set to mofch the pressure or tem perature gauge readings. c. After a differential pressure or tem perature drop, the burner should restart automatically. d. With burner operating in the normal running position, open the blow down volve on the low water cutoff. Burner should turn off, ond restart automat ically when the proper level of water in the low water cutoff is re-estoblished. 24. Air switch check: a. Coveroir inlet on forceddroft blower. Close manual fuel valve. b. Stort burner. Burner should do throw the normol pre-purge ond ignition p riods, but the moin fuel indicoti. light should not be energized. c. After the ignition turns off, the bum should go to flame foilure position. 25. Lotch switch check: a. Open latch switch. Close man fuel valve. b. Turn on burner twitch. Either the bur will not stort, or the oil volvewill i open, depending on control sequer used. c. Adjust latch switch to provide < ti seal between the burner fan Sous ond the windbox. 26. The emergency shut-off switch, if < should be checked to moke sure thol turns off the burner. 27. After the obove procedures have b completed, the operator should be cc fully instructed in the proper mainteno ond service of the equipment. See Ch ter 4, Page 31, of this manual. D. Special Instrucfions-Gas Firing CAUTION: When firing goson ocom bination gos-oil burner which does not rwingout the oil burner while firing gas the shaft seol assembly on the oil burner MUST BE lubricated through the plug in the moduloting oil valve to prevent seal demage. OH line volvesshouldbe kept open to assure pump lubrication. 1. The gos piping, control groups and vol should be checked for compliance v local utility ond the customer's insure underwriter-* requirements. 2. Purge air from gas lines to the lubricc plug cock of the gas burner control gre Some local gas companies require i this be done by their personnel. Ci manual gos cock. 3. Check gas burner linkage. This link, was set by the factory when the bo was Tire tested but the following setti should be checked to determine whet damage hos occurred which disrupted * 0. Special Inslructions-Gos Firing (Continued) linkoge. The primary air damper (on combination gat-oil firing) should be cbout one-fourth open. Secondary air dempers thould be cbout one-fourth open. The got volume control voive thould be about one-fourth open. 4. Set fuel selector switch to "GAS". 5. Check spork gop on gat-electric igniter (1/16"-3/32``). Noturalondmanufactured gas pilots hove a 3/16" gat orifice. Tho LP got orifice it 7/64". 6. Remove top vacuum tube in the R--478B end push fob on top relay. Thit will provide a constcnt pilot during the Part ing operation. On the Fireye FP-2 control a eontfont pilot it secured by replocing the four-pronged AC line plug with a three-pronged test plug, and turning the knurled knob on the timer to the desired phose of eperoting sequence. 7. The pilot flome should be carefully checked for proper operation. A reading of 100 tj 140 DC voltt thould be indi cated from the lett Jacks on the R-478B control. A reading of between 70 and 90 DC volts should be Indicated on the Fireye control. The got pilot normally reQuiret 2"-4" w.c. pressure for natural or manufactured got. Adjust the pilot got pressure regulator os necessary to secure a good stable pilot flame with no fluctuar'-.n in voltage readings. 9. To light off the got burner, set the manual potentiometer in a "closed" position. Turn on the burner switch. The burner will go through its pre-purge period, the pilot will turn on ond be proved, per mitting the moin gas valve to open. At this time, slowly open the closed manual gas shut-off voive. If the got piping wot properly purged of oir, the moin flame will be established almost immediately. If the main flame it not established quick ly, fum the manual potentiometer up so that the gas volume control valve will open further. 9. As soon as a stable flame is established, hold the fire in this position by means of the manual potentiometer for a period of about 30 minutes or until the woter in the boiler is warm. )0. Bring the unit to high fire by turning the manual potentiometer to the "open1' po sition. Be sure thot the monual gas shut off valve is wide open. JJ. Check gas ring pressure gouge. The ring gas pressure required for full firing copocity is stamped on the burner label. 12. Clock gas meter for firing rale. Be sure to check ony necessary meter pressure correction factors with your local utility. Firing rate may be increased or decreased by adjusting the gas pressure regulator. Adjust firing rote -to conform to standard specifications. 13. Change the burner firing rate from high to low several times by means of the manual potentiometer. Check CO2 of high, low, and intermediate fire. The Kewonee unit should not require any major firing ad justments since it has been factory fired and tested. If minor linkage corrections are necessary, see the Service section of this manual, Poge 40. Adjust fuel-air ratio to ochievea combustion roting of 8-1/2 to 10percent CO2 by flue gas analysis with no CO. 14. Restart burner several times to check For smooth light off. 15. Moke flame failure cheek using proce dures outlined in Porograph 21, Poge 24. 16. Make ignition failure check using proce dures outlined in Paragraph 22, Page 25. 17. Make 1 imit control check using proce dures outlined in Paragraph 23, Poge 25. 18. Moke air switch check using procedures outlined in Porograph 24, Page 25. it*.,.. 26 ^J- 0 0 0 0 9 9  ( J^rgSa^ifi^nraysgSaC^:=S^^ FORCED DRAFT SCOTCH PACKAGE UNIT . D. Special lnslrucl!on*-Ga Firing (Continued) 19. Moke torch switch check using procedures outlined in Paragraph 25, Page 25 . 20. The emergency shut-off switch, if ony, should be checked to moke sure thot it turns off the burner. 21. After the obove procedures hove been completed, the operator should be care fully instructed in the proper mointenonce ond service of the equipment. See Chap ter 4, Poge31 of this manual. E. Special Instructions - Gas-Oil Firing T. Set fuel burning equipment in occordonce with the specific instructions listed in this chopter for oil firing. 2. Adjust burner in occordonce with the spe cific instructions listed in this chopter for gos firing. CAUTION: Observe oil burner shaft seal lubrication requirements on Poge 25. 3. Linkoge forges volume control volve may be adjusted os required without chonging the setting of the linkoge for the oil con trol valve. 4. Keep the primory ond secondary oir set tings matched for both fuels so that no adjustments are necessary when changing fuels during normal operation. 5. On combination gos and No. 6 oil, do not permit the No. 6 oil to "set up" in the oil tank.and lines. Keep the tank heater in operation ot oil times. 6. The change from gos to oil requires: a. On No. 6 oil, set oil pump switch in "manuol" position prior to change over to assure on adequate supply c oil ot proper operating temperature b. Shut off burner switch. c. Remove plostic cone cover, swing oi burner in position and close latch switc1 (units with lwing-out oil burner or rongements), d. Chonge fuel selector switch from "gas to "oil". e. Close moin gos shut-off volve. f. Turn on burner switch. 7. Change from oil to gas requires: o. Shut off burner switch. b. Swing-out oil burner, insert plosti cone and engage cone swi tch (uni ts wi t swing-out oil burner orrangement). c. Chonge fuel selector switch from "oi to gas . d. Open main gos shutoff volve. e . Turn on burner swi tch. f. Caution - do not close gate valves i - oil lines to unit with integral pump c any time burner is operating, excep , on swing-out oil burner orrongement g. On No. 6 oil, the oil pump switcl may be set on either "Manual11 o "Automatic". Do not turn off sourer of heat to tank heater. F. Special Instructions-Boller 1. All new boilers, as well os the steam orx water piping connected to the boiler contoin oil, grease, and foreign motter. I is essential to clean the system becousi these 'materials ore responsible for sucl difficulties as overheating of metal, foam ing ond priming, ond high maintenance costs on strainers, traps ond vents. 2. On steam systems, condensate may be wasted for several doys or until tests show the elimination of undesirable impurities. 3. On hot wafer systems, chemicol cleoning is generally necessary ond the entire sys tem should be drained offer treatment. 27 45 000100 <3 28 FIG. 3-1-- TYPICAL GAS-OIL WIRING DIAGRAM FORCED DRAFT SCOTCH PACKAGE UNIT FIG 3-2 --TYPICAL GAS-OIL CONTROL EQUIPMENT ITEM l 3 3 4 5 4 7 f 10 II 13 13 W 13 14 17 11 1* 30 31 a a 34 33 " 34 27 ,, a a 31 a a 34 a 34 V 33 40 41 43 43 44 43 44 47 4 4? 30 31 33 34 33 34 37 * 34 if DESCRIPTION TimIvw 33&m5V 3-7#1* Ivm Week 3-P.I* Km IM 2-7#!* fwta Week 3-^ela Km He*W Km Uadi Map"**'* l*W iPvtw JMpwNt Mepnetic imm 7'wW<pf I15/J4V Paler IrWicerinp lamp ** white Indicating Iwp -- awfcer Jndicetiftf lif ~fW Jn4i<etiftf fwp -- rad 1*5.7. HJC7 Haidar with I cnp. Km 5.7.3.7. Upplawltch 3.7.3.7. Tepglewitch 4-7.o.r. s-i'ck 5.7.0.7. T*9U~;fc D.7.D.T. Tapplawieh Manual pNMiWHf 7en*inel taip Spare lar]nl| Fwcad 4ll fan Mr C11 Wpw mm ll kMMf 71etri ail Imw (MPI AU W(C> Ux)> PvIHK (an til blfw) inMleah Selaneld ail *! Medulerinp mm Maduleting mm t*4 witch FlaM batecM (3cvm) One cane Mitch Ignition trenaHarwr Ignitien pea ealva Oil pu*a mm Modulating untal ItaryaCT witch (Vr *4an) lw mm c<alf with claa witch 3efetp high liatii central Opattirp Haul central Ma<* pa d<n aih aailiay witch Oil Maatiwt central Circulating nw pM M-alneH FUNCTION ClAlrii k(il pw*r IMW 7eri4 4fl1Ian mm circuit Km Oil Kara* mm circuit Km tUci all Imw circuit Km Oil MM cWuil lute (lMH fwwp P wlj) C*aRI cifvtl Km farced 4ll lA MM IMM Oil mm iivia tlecaic ail KmM cmmm Oil p\**p MM IMM uni* enjf) Madufcrinp mm p*>w kcfljr i4 Am wpiI intfitllVI l|AtliM irWitlW M* Kal MiciM hm (*)* MUm Im mm CmmI circuit Km |UM Circulating mm puny witch -- mmIT (telMwater-liw W 4**w umH mIt) FmI mImnt Oil pm mm r-irch, Medulctinf MM witch -- wO.MMC, Medulefinp mm canael -- cleanmpen Wiring (mmoIm Sm wiring liiyw ?n until cabinet S>l<n4ry clr hfclp Drive* awnicar, prinurjr air Kn, alt pup (intake! pup wii* enljr) Hae* ail la *aMtic| aa OH taMraMC I<m witch, cmmIi aparetian af eleanic ail Kmm Seferjr witch Rte*ing iiun4ay air Warp witch p** ail Wnar lacked In pa*Irian Warp witch praving ptMf air {1/ uwd) tic ail cl<n Macular** Knl^lt tuwif Frava imi inwlech Mention pilat end m flvae Wtrp witch pre*ac pee oaw tacked in paaitian Preside* atrt W Ignitien Axaaiit pilat pa valve Circulate* ail ka<* wdr m Wtm 0t*Mte pump u*la anljrl CwMil wdJeting mm in ferae la haat deawid laMta emergency witch M ki* a# hna 5tap* hsrwt w law vattr aarWitlan 3afarp ll*ii * apererlnp canaal Jm* an4 itap* Wrrw In lapaM hallar pvaw^a ar twaaitut Automatic pa valve *rl*> aja claatnp alary htmt Oparata CKcJannp mm puap (k*la>Mar4ia ail haaw unic anlp) Circuiata haiiar mm MwpK veter-te^ll all SaaM (Mlaw wcm-ISm all 4mm uic anlfl Sm wlrlnp 4iMw la wwm! i^iwt ( " ^oooioa ^^jggpfcJiWiLjiAuw.-1 --1--------------- ---------------------------------------------- SgzassgTgiMlm.'Md mcar rottcED DRAFT SCOTCH PACKAGE UNIT F. Special Instructronj.Boiler (Continued) 4. The boiler installer should use the follow ing procedure in washing oil, grease, and j other impurities from the new boiler: < c. Remove fhe safety or relief valve. b. Close the valve in the steam or flow ! line. c. Add caustic soda and soda ash (equal ports) to the boiler water through the safety or relief volve opening at fhe rote of one pound for each five horse power of boiler rating. See Figure 1-1, or 1-2. Fill boiler with such treated woter to middle of gougegloss. d. Remove any controls or accessories uthsaedt .may be domoged by the chemicals e. Provide a pipe connection from the safety or relief valve opening to a convenient drain to serve os a vent. f. Fire the boiler at a low rate, suffi ciently to keep fhe boiler water at steaming temperature, allowing the generated steam along with entroined water and impurities to dis- chorge through fhe vent. With a hot woter boiler keep temperature ot obout 210F. Feed water to the boiler as re quired to maintain the water level in the gloss. It may be necessary to stop burner if woter leaves the boiler through the vent foster than it can be odded through the feed line. With a hot woter boiler keep woter trickling from vent. g. Continue the boiling process for a minimum of.8 hours. Longer boiling time is recommended for 125 horse power boilers ond larger. Up to 48 hours boiling lime may be necessary for unusually difficult Job applications. h. Drain boiler while hot; then remove the manhole cover and all handhole covers. i. While fhe boiler is still warm, flush in ferior surfaces -with water from a hose nozzle under full pressure until all troces of dirt and impurities have been removed ond the wafer coming from the boiler is clear. Start at the top of fhe boiler and work down.. {. Repeat the boiling process if necessary to insure a clean boiler. FORCED DRAFT SCOTCH PACKAGE UNIT MAINTENANCE PROCEDURES A. General Maintenance 1. After the burner has been started ond odjuited by your Kewanee service repre sentative, linkoge settings, fuel pressures ond temperatures should not be chcnged or tompered with by persons not thor oughly experienced with the burner ond fuel system. Service colls caused by "finkeritis" or poor maintenance proce dures ore not covered by any "free serv ice" plon. 2. It is preferoble to keep a No. 6 oil fired boiler in operation, rother than shut down over week-ends or other off periods, less difficulty and better overall economy will be obtained by keeping the boiler on instead of allowing the entire system to cool off. Control arrangements ore avail able to provide o low pressure or temperoture in the boiler during such periods. 3. Keep o constont check on the fuel supply. Do not depend on "automatic delivery"' - watch the supply yourself. Check fuel gauges on the oil tonk (or on the IP gas tonk, if LP is used for ignition). Keep frock of the supply ond re-order before the tanks are empty. 4. Keep the boiler, the burner, and the en tire boiler room clean. Do not allow fuel to leak anywhere - it is dangerous. A clean boiler room is essential to firstclass boiler operation. 5. Keep the burner control cabinet door closed. The electrical contacts in the cabinet are very sensitive to dust ond dirt. 6. Never close vents supplying air to the boiler room. If cold air currents cause difficulty with other boiler room equip ment, air ducts should be installed to di rect the flow of fresh air. 7. Repair all leaks promptly. All piping con nections to the boiler ond oil accessories should be maintained leok-proof becouse even a minor leak, if neglected, may sonn become serious. This applies especially to woter column, water gloss, woter level control piping, ond monhole and hondhole gaskets. If serious leaks occur, shut down boiler immediately and grodually reduce steam pressure. Do not ottempt to moke repairs while the boiler is under pressure. 8. Focming or priming may occur in o steom boiler ond cause large quantifies of woter to pass over into the steom main. It can be detected by violent fluctuations of the water in the glass or by sudden dropping of the woter level in the glass. This trou ble may be caused by dirt or oil in the boiler water, on overdose of boiler com pounds, carrying too high a water level in the boiler, or a high overload on the boiler. In case of serious trouble, stop the burner ond decrease the load on the boiler. Then alternately blow down ond feed fresh woter several times. If foaming does not 'stop; cool, empty ond wash out the boiler ond refill with fresh water. 9. Any problem in regard to extreme fooming or priming, scale in boiler, corrosion or pitting should be referred to a concern specializing in boiler woter chemistry. Do not experiment with "home-mode" treatments or compounds. 000104 1 fOXCED DXATT SCOTCH package unit A. Central Maintenance (Continued) TO. A boiler filled with raw water should not be left idle. The water should first be boiled with the steom chamber vented to drive off any dissolved gases. In the cose of hot wafer boilers, heat the water in the boiler to 200 for the same reason. The boiler water should then be mode alkaline with caustic soda. Use 1.5 ounces of ccusfic sodo per 100 gollons of water conlained within the boiler. 11. Coution, do not odd large quantities of cold feedwater to a hot boiler. C Weekly Mainfenane# 1. Check boiler flues and clean if necessary. The frequency of flue cleaning will de pend on'the fuel used, the burner setting, ond other foe ton of the job performance. Protect burner and controls from dust ond dirt during tube cleaning. Make sure linkoge and other relatively light parts are not domaged. 2. Check oil burner linkages, tighten if necessary. 3. Note condition of belts on belt-drive oil pumps ond burners. Have spare available and replace before the old one breoks, 8. Daily Maintenance 1. Cleon atomizing cup if necessary and moke sure surfoce is smooth. Never use a shorp instrument on the cup. If cup be comes damaged, replace It. 2. Check to moke sure cup is in t^e center of air nozzle. Cup should protrude t/ld" to 1/8" from the nozzle. 3. Clean scanner. 4. Check oil temperature if heater is used. 5. Check boiler water level in the glass and the steam pressure on the gauge on steam boilers. Check temperature reading and water pressure on hot water boilers. 6. On high pressure steom boilers,blow dawn at least one full opening and closing of blowdown valve, except where the omount ond frequency of blowing down are deter mined by chemical analysis. 7. On high pressure steam boilers, the gauge cocks and the blowdown valves on the water cutoff, water column and water glass should be operated to moke sure these connections ate cleor. 4. Test the low water cutoff by turning off the water supply, opening blowdown valve to remove rust ond dirt, and'then observing whether or not the burner cuts out with low water in the glass. 5. O.i low pressure steam boilers, the gauge cocks ond blowdown valves on the water column and water glass should be oper ated to make sure these connections are cleor. D. Monthly Maintenance 1. Check ignition assembly and electrode. Clean if necessary. 2. Check primary and secondary air dampen. Remove any accumulation of lint or dirt. 3. Inspect condition of refractory. 4. Inspect oil strainer screen ond clean if necessary. The frequency of cleoning oil stroinen will depend upon the quality of oil in use. Be sure the cop gasket Is In good order ond mating surfoces clean. A light coot of clean grease will help se cure a vacuum-tight joint. Note - close the gate valve ohead of the strainer be fore removing the cap to prevent loss 32 Ar 000105 FORCED DRAFT SCOTCH PACKAGE UNIT D. Monthly Maintenance (Continued) of oil prime. Turn off oil pumps while cleoning strainer. 5. Lubricate motors in accordance with mo tor manufacturer's instructions. 6. Check lubricating oil level in burner gear box while burner is turned off. Add Kewonee Gear Box Oil if oil level Is tow. Da not fill obove test plug level. 7. Lubricate oil burner shaft seal. 8. On low pressure boiler, drotn off a smoll omount of water from the boiler droin valve to remove sediment and rust accu mulation. Don't overdo and waste clean woter. 9. Test boiler safety valves. 10. Cleon stop-drip trap inside otomizing cup. See poge 37. E. Annua! Maintenance 1. Hove the burner inspected ond checked by yourlocol Kewonee service representative. 2. Drain and flush burner gear box. Refill with Kewonee geor box oil. 3. Replace vocuum tubes ond scanner cell in electronic controls. This replacement is inexpensive insurance ogainst future serv ice colls. 4. Drain ond clean sediment out of electric oil heater ond boiler mounted oil heater. 5. Check condition of oil tank. Clean ond remove sludge if accessory. 6. If the boiler is to be out of service for the summer, be sure to break all power con nections to the boiler ond auxiliaries. 7. To protect the fire side of the boiler frcr. corrosive oction of combustion deposits scrope all carbon, rust, soot or other de posits from fire surfoces. Apply thin coat ing of oil or grease if boiler is to remoir out of service for the summer. 8. To clean woter side of the boiler, removr all monhole ond hondhole covers. Hosi the inside of the boiler with woter unde high pressure ond use hand scrapers to re move ony mud, scale, etc. Storf at fop o boiler ond work down. 9. Coll for boiler inspection if required b) your state, municipal, or insuronce ogencies. The boiler must be fully occessiblr both inside ond out for the inspector. 10. Since local conditions determine the use of wef or dry storoge during summer shut down periods, information as to type of boiler protection required should be ob tained from yourboilerwater consulfont or insurance company. 11. Wet storoge. See that the feedwater and steom connections ore tight. After a light steaming period vented to thi otmosphere to expell dissolved gases, completely fill the boiler, odd sodium sulfite (approxi mately 1.5 lbs. per 100 gollons of added feedwater) and coustie sodo (oppraxir ely 3 lb* - of coustic sodo for 1000 gal lons of woter within the boiler) to provide a protective concentration of chemicals. Tests should be conducted occasionally to make sure that the boiler is properly protected. 12. Dry storoge. Drain the boiler, cleon it intemoily, and then oir dry It thoroughly. Boiler room should be kept dry and well ventilated to prevent boiler surfoce corrosion. A5 000106 FORCED DRAFT SCOTCH PACKAGE UNIT ERVICE PROCE A. Adjustments And Repairs The Service Procedures deloiled in this section oF the manual are intended os o guide in mak ing certain repairs and adjustments which moy be necessary during the operating life of the Kewonee Unit. Many of these repoirs con be made by any boiler operator, others should be made by a skilled serviceman. Coll your au thorised Kewonee Service Representative for dependable service assistance. REPLACE WATER GAUGE GLASS: T. Close woter glass shut-off volves, open glass drain cock, remove guard rods, re move gloss, cl eon openings. . 2. Make sure new gloss is proper size ond length. 3. Insert new gloss, use new rubber gaskets. Take core not to set stuffing box nuts too tight. 4. Open top volve slightly. When gloss is warm, close drain cock. Open bottom volve slightly, check for leaks. 5. When woter level has become stable open both volves, reploce guard rods. APPLY MANHOLE AND HANDHOLE COVERS: 1. Clean metal surfaces where cover plate bears against shell plate. 2. Always use new goskets. Apply graphite pcste or grease to gasket to prevent sticking and secure tightness. 3. Use care in centering cover plate and gasket in shell opening. Draw bolts up firmly. Tighten If necessary to moke leak proof when roising steam pressure. REMOVE BEARINGS: T. Remove the oir nozzle, otomizer, front holf of fon housing ond the fon from the front end of burner. 2. Remove the moduloting valve, belt guord and odopter, seal and pulley from the back end of belt drive burners or remove motor stator (including odopter ond end bell) and rotor from direct drive burner. 3.. Remove upper pump bolt which would Interfere with shaft removal on KP Models 83 through 93. 4. Remove oil screws holding beoring cops to gear box. KP Models 80 through 62 do not have a fan-end beoring cap. 5. Tap the seal end of the shaft, using a block of wood for o cushion to prevent domoge to the shaft until the shaft slides out of the rear bearing ond drives the front bearing out of the gear box. Twist shoft while topping to disengoge the worm and gear of pump. 6. The fon-end bearing may be removed from the shaft by placing a yoke behind the beoring or oil stinger and topping the drip trop on the end of the shaft. Use extreme core to prevent domoging the threads. 7. To remove the rear beoring from the gear box, insert e wooden dowel through the fan-end bearing opening ond tap until the rear bearing is forced out of the gear box. Remove retaining rings and tap bearing out of bearing cap. 4-S 00010$ FORCED DRAFT SCOTCH PACKAGE UNIT A. Adiuilmtnlt And Rtpain (Continued) REFtACE REARINOIt 1. New beorings should be special high-- lemperoture packed beorings similar to New Departure. 2. Press fon-end bearing ond slinger onto shaft until shoulder on shaft is exposed. 3. Press recr bearing into bearing cap and/ or gear box. 4. Insert shoft into front hole of gear box and through rear bearing, twist shoft to engage pump gears, apply force to fan end of shaft until shoulder on shaft oppeon at rear bearing bore. It will be neeessory to hold the reor bearing in ploce by use of tubing egoinst a solid object while inserting the shaft. 5. Tap ends of shoft lightly so that beor ings may be relieved of any strain and reassemble burner. REFlAd PUMP GEAR: 1. If the lubricating maintenance proce dures outlined in Chapter 4 are ob served, pump gear and worm should never require replacement. 2. To remove pump gear drive, the pump must be unbolted from the burner assem bly. The new gear must be placed in exoctly the same position as the one re moved so that the new gear is in exact alignment with the pump worm. The originol factory dimension between the inner edge of the pump odopter and the outer edge of the pump drive gear wheel is 2-11/16" on Models 80 through 82, and 2-5/8" on Models 83 through 93. 3. The main shoft must be token from the burner in order to gain access to the pump warm. Follow the procedure de tailed in "To Remove Bearings". REFIACI ROTOR (MODELS ROJOi 1. The rotor is mounted on o bushing which Is fastened to the shaft by a left-hand thread lock nut and a key type washer. Use core not to distort the lock nut or washer. 2. Be sure that the faces of the lock nut, washer, ond rotor bushing thof contoct eoch other are clean and lightly oiled before replacement. 3. After tightening the nut, check the shaft to make sure that It runs true. If a high point is found, the shoft con be straightened by firmly topping to tight en the lock nut (not the shoft) at a point directly above the high point. It is important that the shoft run true to ovoid vibration. REFLACE FRIMARY AIR FAN: 1. The primary air fan is held on the moin shaft by two set screvsa which press against keys inserted in fan keyways. 2. To remove the fan, loosen set screws ond push fan bock on the shaft. Remove keys,ond clean the main shaft carefully. 3. Use hand pressure between the outer edges of the fan and the fan housing to pull the fan off the shoft. Do not force the fan off by prying. 4. If fan cannot be removed from shaft by cleaning the main shaft, a fan puller must be used. This Is available from the factory. 5. Before replacing fan, clean any burn or carbon from main shaft, fan keys and bore of fan. Smooth slide fit is necessary. 6. Hold keys on shaft flats with a piece of string wound several times around shoft and keys, leaving one end of string dangling below fan diameter; slip fan over shaft and keys until fan will hold " /f.5 000109 S X B H i i - 1 - R IX FORCED DRAFT SCOTCH PACKAGE UNIT C A. Adjustments And Repairs izing cup should extend obout 3/32 of (Continued) on inch forward of the lip of the air nozzle. The position of the oir nozzle keys; withdrew the string by pulling on the end. can be changed by loosening the clomp bolt. 7. Push fan toward gear box to within 1/16 to 1/8" from the rear fon housing. Tighten set screws and spin fon to moke sure it does not rub on the fon housing. Reossemble and turn by hand to moke sure the fon clears the front fonhousing. SERVICE ATOMIZING CUF: SERVICE STOF-DRtF TRAP: 1. The stop-drip trap is located inside the otomizing cup, fostened to the moin shoft with right hand threods. The otom izing cup should be removed before re moving the drip-trop. See Fig. 5-1. 1. The oil atomizing cup moy be cleaned by swinging the burner owoy from the firing position and inserting a soft cleoning cloth inside the cup; light oil or solvent moy be used to remove oil deposit. 2. To remove the cup from the moin shoft. Tint remove the oir nozzle, then un screw the cup from the main shoft. Do ( not use a wrench on the atomizing cup. A quick twist of the cup should loosen the thread which is regular or right bond threod. 2. The drip trap, which prevents oil in the hollow burner shaft from leaking into 3. Do not use hard or sharp instruments the otomizing cup during the off peri in cleaning the cup. If the lip of the ods, must be cleaned periodically. Re cup becomes slightly burred it may be move the drip trap, soak in kerosene or smoothed by using fine emery poper. solvent, wipe dry ond reploce. 4. If cup is damaged or burned, reploce it. ADJUST AIR NOZZIR: 1. The oir nozzle may be removed from the front fon housing by removing two bolts. 3. If oil still leaks into the atomizing cup while the burner is shut down, check to make sure the drip trap is tight ond then check the solenoid oil valve which moy be seating improperly. 2. To odjust the variable voned oir nozzle For either o longer or wider flame pat tern, release the two set screws holding the tapered portion of the oir nozzle to the moin body of the nozzle and turn the tapered portion until the air vanes ore at the proper angle for the desired flame pattern. 3. The air nozzle must be centered exactly around the atomizing cup. The otom- REPLACE SHAFT SEAL: 1. The purpose of the shaft seal is to per mit fuel oil to flow from the stationery rear end body into the rototing shoft without leaking. If the motor moin shoft hos to be removed for ony reason or if the seal leaks, as shown by o drip of oil from the leok hole ot the bottom of the motor housing, a new seal should be installed. 37 AJ 000110 FORCED DRAFT SCOTCH PACKAGE UNIT A. Adjustment* And Repair* (Continued) 2. Complete Instructions on replocing the rolory leol unit ore included with each leal lent from the foctory. SERVICE Oil PUMP: 7. Both integral and eporote oil pumpi ore Tulhill pump! of the internal geor type with a roted eopacity of opproximolely 200% of the burner firing rote. 2. Field replacement of Internal port! of ony of the pump!, uch at the teal, gears, or shaft, is discouraged. A foc tory overhaul or a complete pump as sembly replacement It suggested since failure of one part usually indicates foilure in other ports. 3. High eopacity ouxiliory pump sets. Sires 5 ond 6, use a lip type seal which moy be replaced In the field. Trouble CHECK Oil PUMP OPERATION Possible Cause A. No oil delivered 1. Pump not primed 2. Suction lift too high 3. Air leak in suction line 4. Wrong direction of rotation 5. Worm or geor slipping on shaft 6. Pump gears wom 7. Pump seal leak B. Ccpacity too low 1. Suction lift too high 2. Air leak in suction line 3. Suction line too small 4. Check-valve or strainer too small or obstructed 5. Mechonieol defects: (o) Pump bodly wom (b) Packing or seal defective C. Pump is noisy 1. Pump not securely mounted. 2. Vibration caused by bent shaft or misalignment 3. Pump overloaded 4. Air leak in suction line 5. Suction lift so high that vapor forms within the liquid 6. Loose pulley 7. Viscosity of oil too high for the pump speed 8. Bells worn 38 ^5-oooUi a *-. C if *- FORCED DRAFT SCOTCH PACKAGE UNIT A. Adjustments And Repair* (Continued) Trouble D. Pump leaks CHICK Oil PUMP OPERATION Possible Cause 1. Cover bolts need tightening; gasket is broken or defective 2. If pocked pump, packing may need tightening or replacing 3. If mechonicol seal pump, seol may be scratched due to dirt 4. Pump bushings ond other ports badly worn from obrasives in fuel oil SERVICE VISCOSITY VALVE: 1. The viscosity volve is used to meter the desired quantity of oil to the otomizing cup. Excess oil is returned to the tonk. The valve also includes on emergency relief feature in case of on unusual condition such os complete closure to the return line. 2. The only field service recommended for the viscosity volve is thol of cleaning to remove particles of sediment or carbon. To clean the valve remove the cap from the bottom of the valve, drain and flush out ony accumulation of sludge or dirt. 3. Viscosity volve stems hove a left-hend thread. REPLACE HINGE SEALE: 1. Be sure the lotch holds the fan housing tight to the front plote. Support the burner with blocks under gear box to relieve swing joint hinges. 39 tmes*- 2. Open unions outside of swing hinge, between swing ond burner pump, and on electric oil valve. 3. Support electric pre-heater pipes and valves connected to it on blocks. 4. Remove Altenheod screws from the hinges. Remove the four hinge pieces after marking them so thot they con be moted when reassembled since they ore not interchangeable. 5. Pull back the swing manifold ond oil parts connected to it until it is cleor of its hinges. 6. Pull top and bottom sections from the swing manifold body. Clean the sec tions thoroughly, being eoreful not to scratch ony port of the groove in which the "O" rings set. 7. Roll new "O" rings into the grooves. Lubricate the "O" rings and the grooves, push the sections into the body of the swing monifold ond reassemble. Be careful not to cut or nick the "O" rings. AS 0 00112 FORCED DRAFT SCOTCH PACKAGE UNIT A. Adjustment* And Repairs I (Continued) 5. Individual heoter elements may be dis connected from the power source with out affecting the operation of the other elements. SERVICE GAS-ELECTRIC IGNITER: ^ The igni ter assembly should be removed and cleoned regularly. The porcelain Insulator should be kept clean end the entire electrode must be replaced if the 6. Coution - Remove the oil heoter thermostot before removing the element plate in order to prevent damage to the thermostat sensing element. insulator is cracked. Cleaning may be done yrifh solvent. SET LINKAGES: When the electrode is replaced, a spark gap of 1/16" to ty'32" must be left be tween the electrodeand the igniter body. 3. The orifice located in the base of the pilot nozzle should be kept clean. The no rural or mixed gos orifice is 2/16". The LP gas orifice is 7/64". The curved slot tinkoge is designed to simplify adjustment of the correct proportioning of air to fuel ratio for both high ond low fires with out low fire adjustment interfering with the high fire adjustment. A. ASSEMBLY Of LJNXAGEj 4. The high tension wire between the transformer ond the igniter electrode should be checked periodically for deterioration. SERVICE ELECTRIC OIL HEATER: 1. Do not set oil heater temperature too high. Excessive temperatures may cause gasification or carbonizing, resulting in unsatisfactory starting conditions ond shortened life of heoter elements. 2. Electricity should be shut off to the heoter and controls when doing any work on the electric heater. 1. Jock shaft or quodront must be in high Fire position before assembling. See figure 5-2 and Figure 5-3. 2. Drive arms are secured to jock shoft by tightening the two set screws after set ting the drive arms in the 45 position. The connecting rods driving the quad rants are shortened or lengthened by loosening the set screw in the square boll ond socket joint, sliding the con necting rod through the socket joint un til the 45 position is found. Tighten set screw in the ball and socket joints. 3. The nuts holding the elements to the plate and the nuts holding the plate to the body should be tightened as neces sary to prevent oil leaks. Install a new gasket to eliminate serious oil leaks around the element plate. Soak the new gasket in lubricating oil before install ing. 3. With the ball and socket joints ond the connecting rod in place as in Fig. 5-3, adjust the rod length so thaf sliding the square boll and socket joint (when loose) in the curved slot arm (during high fire position) will not moke the curved slot arm move. Leave ball and socket at outer end of slot until later. ' B. WHEN THE LINKAOI IS PROPERLY ASSEMBLED..' Sliding square ball and socket joint:1 in slot of arm during' FORCED DRAFT SCOTCH PACKAGE UNIT A. Adjustments And Repairs (Continued) high fire position does not change setfing of domper (or oil volve, gal volve or secondary oir dampers). 2. Sliding square boll and socket joint back and forth in slot of arm during low fire position does chonge setting of domper (or oil volve, etc.) from approx imately 20 to 90 movement. If less movement is desired. The ongle boll joint moy be screwed into onolher hole ' of jock shofi drive arm, but connecting rod must be reset so that high fire posi tion is properly odjusted. 3. The slot of the primary oir domper stem is nearly horizontal (damper wide open) during high fire. If more, or less, prim ary air Is desired, loosen the two set screws in the curved slot arm sleeve, turn the stem sfot to the desired position ond tighten both set screws. 4. The secondary oir dampers should be odjusled to deliver as much air as is required for a eleon efficient fire. If more, or less, secondory oir is desired, loosen the two set screws in the curved slot orm sleeve, turn the stem slot'to the desired position and lighten both set screws. E. LOW FIXE LINKAGE ADJUSTMENT OF THE OIL C. 1. All LINKAGE ADJUSTMENTS AXE MADE AT BUKNEX: HIGH FIRE POSITION AND THEN ADJUSTED to low me POSITION. 1. To adjust oil flow, loosen the slot nut on t the ball and socket joint on the modulat 2. Figure 5-3 shows how the linkoge is or- ing oil volve orm slot. Slide the ball ranged or must be corrected to ochieve and socket closer to the stem for less oil the proper finol odjustment without dif ficulty. The linkoge Is driven to the high fire position by switching the mod or to the outer end of the slot for more oil. Tighten the slot nut on the boll and socket joint when desired oil volume of low fire is established. Do not odjust ulating switch on the control cabinet to viscosity valve while linkoge Is in low "monuo)1' ond turning the monuol po fire position. tentiometer to ''open*1. To drive the linkoge to the low fire position, fum the potentiometer to "close". 2. To adjust primary air, loosen the slot nut on the ball ond socket joinfon the prim ary oir damper orm slot. Slide the ball D. HIGH FIXE LINKAGE ADJUSTMENT OF THE OIL BUKNEK: and socket closer to the stem for less primary oir or away from stem for more air. Always odjust for os much primary ). Adjust the high fire first. oir os possible, without hoving o rough stort. ' 2. The slot in end of modulating oil volve stem mutt be in a vertical plane. Adjust oil volume of high fire with the oil vis 3. To adjust secondory oir, loosen the slot cosity valve. If stem slot is not vertical nut on the ball and socket joint on the loosen the two set screws in the curved secondary oir domper arm slot. Slide the C slot orm sleeve, turn the stem slot until ball ond socket closer to the stem for less vertical ond tighten both set screws secondary olror away from stem for more permanently. air. 000114 41 FORCED DRAFT SCOTCH PACKAGE UNIT A. Adfu*tment* And Repair* (Conlinued) (from stem end) opens gas valve and vice vena. Finol adjustment may be mode with the screw stop on the volve. Additional high fire adjustment may be 4. If further odjustments ore mode for high fire, the low fire odjustments must olio mode by odjusting the gas pressure reg ulator. be chonged. 3. With the linkage in the low fire posi F. LINKAGE ADJUSTMENT OF CAS VALVE ON COMBINATION GAS-OIL BURNERS: tion, loosen the slot nut on the ball and socket joint in the orm slot. Slide the ball and socket closer to the stem for less T. First, odjust oil burner linkoge as per porogrophs "D" and "E", Page 41. gas or away from the stem for more gas. Tighten nut on ball and socket joint. A minimum setting of the gas volve con be 2. With linkoge in high fire position loos made with the screw stop. en the two set screws in the curved slot orm ottoched to the stem of the gas but- C. On straight gos burners (without oil burner) j |erfly volve. Turning the spring ossem- adjust linkage as per paragraphs Dl, D4, E3 : bly of the gas volve counterclockwise E4, F2, and F3, Pages 41 and 42. 000115 42 FORCED DRAFT SCOTCH PACKAGE UNIT' LINKAGE ASSEMBLY-FRONT VJEW ALL LINKAGE SHOWN IN HIGH FIRE POSITION FIG. 5-2--LINKAGE ARRANGEMENT 43 $5 ooOiiS ------- *-rK*'***=x?zsmer- r mnrn~w*",t""^mw'a"=P^---T^g:r FORCED DRAFT SCOTCH PACKAGE UNIT1 B. Service Chicle Usf (Read Instruction* on Combustion Safety Control) MOSLEM AND POSSIBLE CAUSE REMEDY A. BURNER MOTOR WILL NOT START 1. Switch off 2. Fuse blown 3. Overload relays disengoged 4. Holding coil of motor starter burned out 5. .Limit controls, low fire interlocks open 6. Low water cut-off open 7. Cold-oil lockout switch open (No. 6 oil models) 8. Programming relay in safe position 1. Put switch in `'ON" position. 2. Replace fuse. 3. Press reset button on motor slorter. If motor ap pears to be overloaded, check cause. 4. Replace. 5. Increase setting of limit controls to desired pressure, adjust low fire end switch. 6. Flush sediment out of low woter control. Add water. If necessary. 7. Engoge healer switch ond set preheater thermo stat to desired temperature. If heater does not warm up, elements moy be burned out; if so, re place. If replacement is not available, run a jumper ocross cold-oil lockout switch ond operate burner on cold oil. It Is recommended thota con stant gas pilot be used to maintoin ignition until hot oil is obtained from other preheater*. 8. Press reset button. B. BURNER MOTOR STARTS, BUT NO FIRE RESULTS-IONmON FAILURE 1. Electrode grounded 1. Cleon electrode and porcelain. If porceloin is cracked, replace it. 2. Electrode not set properly 2. Adjust for 1/16" to 3/32" spark gap. 3. Defective transformer 3. Reploce. 4. Failure of gas sypply, or pressure too low 4. Cleon magnetic go* valve; make certain that valve is operative. Test pressure. 2"-4" w.c. recommended. Often all valves in gas line. 5. Go* flowing owoy from spark 5. Gas pressure too high. If over 5" w.c., adjust pressure regulating volve. Forced secondary oir may blow out pilot; If so, shield pilot, or reduce size of low fire. 6. Scanner does not see pilot flame 6. Remove, clean and reset. mm* 45 fi-S 00011$ tsaasBxsaaaaBaBsaBsss FORCED DRAFT SCOTCH PACKAGE UNIT V, B. Servlet Check Uil--Continued PROBLEM AND POSSIBLE CAUSI REMEDY c BURNER MOTOR STARTS, IGNITION PHOT OBTAINED, BUT NO OIL DELIVERED 1. Oil volvei closed 2. Storoge tank empty 3. Strainer or viscosity valve clogged 4. Air in suction line 5. Solenoid oil valve not opening 6. Water in fuel 1. Open gate valve in suction line; open viscosity valve, gate valve, and moduloting valve on burner. 2, Fill. 3. Cleon strainer or valve. 4. Purge line of air by keeping oil pump in operation and checking suction line for possible air leaks. especially at strainer ond swing [oinfs; prime strainer. 5. Coil moy be burned out; replace. Volve moy be sticking; clean with kerosene or solvent. 6. Pump sludge from bottom of oil storage tank; drain strainer body. D. FIRE PUFFS BACK AT START 1. 8reeching domper closed 2. Oil too volotile 3. Gcj pilot not In vicinity of otomizer 4. Improper oir and oil mixture 5. Low fire stort E. PULSATING FIRE 1. Fire too lean 2. Air in oil 3. Fire too small 4. Belts too loose 5. Loose secondory oir vones 1. Open. 2. Oil temperature may be too high. 140 to 180 recommended for No, 6 Oil. 140 maximum for No. 5 Oil. 3. Pilot possageway must aim towords atomizer ond flame should reoch lip of otomizer. 4, Set mixture of oir and oil for the most efficient fire. 5. Reduce primary oir ond/or quontify of oil. 1. Cut down oir supply. Adjust secondory ond pri mary oir. 2. Eliminate oir by tightening and purging oil lines. 3. If minimum fire is desired for normol operation, a smaller oir nozzle may be used. 4. Increase belt tension so that no slipping results. 5. Secure vanes and tighten linkage. oooii^ 46 5*i * *>3S*W Vw*--'- j* *^' i7,f'*`" fORCED DRAFT SCOTCH PACKAGE UNIT. B. Service Check List--Continued rxoaiEM and rojsmr cause I. PULSATING FIRE (CONTINUED) 6. Insufficient combustion oir REMEDY 6. Provide oir Inlets to boiler room, 125% stock area minimum. F. BURNER RECYCLES TOO OFTEN 1. Limit differential set too low Z Low water level set improperly 3. Surging woter level 1. Increose limit differential. 2. Adjust setting so that burner is not stopped (with in safe woter levels) before boiler feed replaces water. 3. Priming ond foaming of boiler. Determine cause of condition and remedy. 0. NOISY OPERATION 1. Noisy pump Z Combustion noises 3. Noljy bearings 1. Oil pressure too high (35 to 50 lbs.); check ond flush lines, fittings ond valves, See Pope 38. 2. See "E" above. 3. Replace ond check. Remedy couse of bearing failure. H. CARBON PEP0SITS I. Oil impingement 2. No. 6 oil 3. Lack of primary air pressure and volume 4. Dirty oil atomizer 5. Atomizer improperly located in re- lotion- to nozzle 6. Oil atomizer damoged 1. Norrow the flome by use of vaned nozzle. 2. Increose oil temperature. 3. Open primary oir damper. Check burner speed; if less than 3500 RPM check cause (moy be low voltage, foully bearings, loose belts, rotor or fan slipping on shaft, etc.) Fan housing may be foul ed with fuel oil; dismantle ond clean. 4. Clean ond polish with fine emery paper. 5. Atomizer should be concentric with ond project ing obout 3/32" beyond lip of air nozzle. 6. Replace oil atomizer if rim is out-of-round or burned. I. BOaER DOES NOT CARRY LOAD 1. Steam pressure too low 1. Increase limit ond operating control settings. 47 AS 000120 saaa11 j h --- \ iiy: FORCED DRAFT SCOTCH PACKAGE UNIT B. Service Check List Continued PROBLEM AND POSSIBLE CAUSE REMEDY 1. BOIUR DOES NOT CARRY LOAD (CONTINUED) 2. Firing rale loo low 2. Open manual potentiometer. Make sure fuel valves are open. Reset fire if necessary. Cheek linkages. 3. Dirty heoting surface* 3. Clean tubes. 4. Boiler priming ond fooming 4. Drain, flush, condition woter. 5. Fire not efficient 5. Check linkages, reset fire for proper combustion. 6. Gas prejjure foo low 6. Check with locol utility. J. LACK OF HEAT 1. Volves doted 2. Poor circulation 3. Improper distribution 4. Cold oreoj 5. Boiler not carrying lood 1. Open supply and return valves. Check zone valves. 2. Check circulating or condensate pumps. 3. Check temperature control system thermostots, valves, traps. 4. Check heoting units, volves, coils, bikers, fil ters, traps. See "I" obove. W . --<............. 1 j I PARTS PROCEDURES A. Ordering Replacement Parts WHERE TO ORDER FARTS: Parts for Kewonee units should be ordered from the authorized Kewonee Service Repre sentative who started and adjusted your unit. His name is listed on the first poge of this manual or on the Operoting Instruction Card. If necessary, ports may be ordered direct from Americon-Stondord Industrial Division, 101 Fronklin Street, Kewonee, Illinois, or from your loco! Americon-Stondord Industrial Divi sion or Kewonee Soles Office. HOW TO ORDER PARTS: 1. Always include complete nameplate doto as shown on the boiler fiuedoor and on the burner windbox. 2. If ports ore required for electric con trols, motors, pumps, etc., also include complete nameplote dato token from the item for which the parts ore required. 3. List the complete name, description and Kewanee port number of eoch port in cluded in your order. Refer to the Parts List in this manual. 4. State quantity desired of each Item. 5. Stote whether shipment is to be mode by express, parcel post or freight. PARTS RETURNED UNDER WARRANTY OR FOR REPAIR: 1. Notify Americon-Standord Industrial Division, Kewanee, Illinois (or your lo cal ASID or Kewanee Sales Office) of the port to be returned; model and seri al number of unit from which it was taken; whether the port Is being re turned for credit, replacement, or re pair. A Return Material Tog will fc* sent to you. 2. Do not send ony part to the Kewonei plont without a Return Moteriol Tog 3. Remove usable fittings from the part droin oil (if any), cleon, ond oftoch the oppropriote section of the Return Mate rial Tog securely to the part. 4. Pack the port properly to ovoid shipping damoge and ship prepaid to AmericanStandard Industrial Division, 101 Frank lin St., Kewanee, Illinois. B. Replacement Parts Inventory Every boiler plont owner can ossure more eco nomical ond effective operation by purchasing a small inventory of replacement ports for the use of the operator in maintaining ond servic ing the boiler unit. The following suggested list of replacement port* stock is o minimum inventory. Consult yov authorized Kewonee service representot 'e for replacement ports stock odequate to meet the full requirements of your particular job. 1. Replacement electrical fuses. 2. Set of tubes for electronic control. 3. Sconner cell for electronic control. 4. Set of monhole end handhole goskets. 5. Water gauge gloss with rubber gaskets. 6. Ignition electrode ond porcelain. 7. Gear box lubricant. 8. Oil strainer gasket. 9. Oil atomizing cup. 10. V-Belts (for oil pump and V-Belt burn ers only). fi-f 000122 FORCED DRAFT SCOTCH PACKAGE UNIT PARTS LIST INDEX To determine correct name of the vorious ports, refer to the following figures: Poge Fig. 6-1 Direct Drive Burner.................................. 51 Fig. 6-1 Belt Drive Burner..................................... 51 DESCRIPTION PAGE DESCRIPTION page Air Nozzle Assembly .............................. 52 Air Damper............................................. 52, 62 Atomizer..................................................... 52 Beorings and Cops..................................... 53 Belts, Ropes and Sheaves ........................ 57 Clomps.................... 52 Contoctors.................................................. 59 Controls: Variable Fire Motors ondParts............ 59 Motor Starters-lgnition Transformers. . 59 Heoter Contoctors-EnclosedRelays. . . 59 Air and Gas Pressure Switches and Interlocks............................................. 60 Gas Pilot Valves ond Pressure Regulators................................................ 60 Progrom Controls andPorts................. 60,61 Control Cobinet Ports................................ 61 Drip Trop........................................................ 53 Fon Housing Assembly.............................52,62 Fireye Controls..........................................60,61 Front Plate Assembly................................ 52 Gouges ond Fittings................................... 54 Gear Box Assemblies................................ 52 Gear, Pump Drive..................................... 53 Ignition Assembly..................................... 55 Lotch Switch Box and Parts...................... 52 Linkoge, Oil Burner ................................ 55 Main I Soft................................................ 53 Mar'folds: Swing-2 Pom............................................. 55 Gas........................................................ 61 Minneapolis-Honeywell Controls .... 59,61 Motors........................................................ 58 Motor Mount Plate and Parts.............. 58 Motor Starters........................................ 59 Oil Pump ond Ports.................. 53,56 Pump Drive Gear. ......................... 53 Pump Drive Worm........................... 53 Pump Hole Cover.............................. 53 Oil Strainers and Ports........................ 56 Oil Valves and Coils........................... 60 Plostie Cones........................................ 52 Preheaters ond Parts ........................... 54 Pulleys, Shaft and Motor...................... 57 Pump Set Ports..................................... 56 Reor End Modulating Valve................ 54 Relief Valve ..................... '................. 54 Retaining Rings ................................... 53 Rotary Seal.......................................... 54 Rotor Locknut ond Keyed Washer.... 53 Seals: Pump............................................... Burner ............................................. Shaft, Burner........................................ Shaft Slinger........................................ Shut-off Hand Valve........................... Stop Drip Trop..................................... Stroiner Assembly................................ Swing Manifold Assembly................... Thermometer........................................ Transformers ........................................ "V" Belts ............................................. "V" Ropes............................................. Volves.................................................. Viscosity Valve Assembly................... 56 54 53 53 54 53 56 54 55 59 57 57 60 54 .) 50 000123 #! task .AOTON LOCkvaimcn AND LOCKNUT -$NKKT UAL ASSCUiu _*CAL SUSHINO ANO ftuaic* kino SO* DIRECT DRIVE UNITS KOTON CNS ItLL MOTO* KOTO* OTO STATON OtUS KOTO* KULLtT ryi ~ salt SUA* KCTAININt NINO CA (NO ICAKIRO t* OCAKIKO CAP IKAKT PVLLCT SNAfT SCAL ASIC volt SlAl OUSHtKO and NUOOCN KINO CIT UA*D AAAPTOft SHArr ^**<l*R lot mp rve tut BELT DRIVE UNITS PARTS DESCRIPTION DESCRIPTION OIL ATOMIZER (Cup) Stender4 0.0. x length 2 * 4-1/2 2-1/2 * 5 3 k 5-1/2 3 k 4-1/2 ........................... ........................... ........................... ........................... DESCRIPTION UNIT SIZE UNIT SIZE PART NUMBER 80-82 83-85 84-88 89-93 Tcp**od Std. 290024 290027 290028 | 290029 Str.Shot Specie! 290327 290328 290329 290330 PART NUMBI* AH NOZZLE ASSEMBLY Srd. Ls. Bota Box 2-V 2-1/2 3 3-1/8 3-J/B z-y* 3-V* * 44 80-82 83-83 84-88 89-91 92-93 Plain (No VflAt) 290331 290332 290333 290334 290313 Flx*d Von* 2CP C.W. 290334 290337 290338 290339 290340 Vor- lobl. Von* 290021 290022 290023 290024 290025 If C.C .W. rototlon, o different ongfa or forge bore ! desired ^eclfy requirement on order. DESCRIPTION FAN primary Air) Includes Nve key* end Mt tcrtwi. UNIT PART SIZE NUMBER 80-82 83-85 84-88 89-93 2900C8 290009 290010 290011 FAN HOUSING Aamrblr Matched front ond rear housing with baffle plote ond screws end nuts. 80-82 83-85 84-B8 89-93 290000 290001 290002 290003 fAFFJi flAg only (Front Fen Hetaing) tapiocomoAt must be drilled on job using eld plote at template. 80-82 83-85 84-88 89-93 290004 290005 290004 290007 , FRONT PLATE (Burn*) 80-82 83-85 84-93 290341 290342 2903*3 HINGE BRACKET (Front Plot. 1 Died only on forced draft vindbom 80-82 83-88 89-93 290344 290013 | 290014 | PLASTIC CONE (Sool T*l Including Pocking 80-82 83-88 89-93 290348 290349 290350 I 1 1 DESCRIPTION PLASTIC C(?Nf (Standard} Used In til# door or po> manifold PACKING (ArUtto. SmolB 1/4 > 1/4 * 23* for '2*0348 Ffostle Cone . . ................. ... , . 1/4 , 3/8.37" for '290349 and 290350 Plcatle Coot..................... "Todpola " cross section tope for forced droft manifold or tile'door teol a .......... ...........................................24" ......................................................37- PACKING CLAMP Holds todpol# tqpe In monffold or tile door T1UE DOOR CLAMP Holds tile door or goi monifold to forced droft windbox....................... LATCH SWITCH OX AuamMgr Includat ben, Mnpad cov*fJ mounting plata, clamp pleta, ttifftnar, iwltch and larminal ancletwra.................... ... SWITCH only far 290340 ounnfcly............................... TERMINAL ENCLOSURE only far rwltch......................................... LATCH LEVER Assembly includes qpocar end attaching screws.................... ... GEAR BOX ASSEMBLY For direct drive burner* with In* tegrel pump* only. Including ge box body, theft, bearings, pump end gears, air damper, klp trap, retaining ring(i), ifingest), bear* Ing c^(s), L.H. locknut end keyad atm, fan k*yi and all fill cup. GEAR BCX ASSEMBLY For direct drive, pumpleM burner* only, Including gear box body, sheft, bearing*, cover plote, air damper, drip trap, retaining rlng(s), tJinger(s), bearing c^{s), L.H. locknut ond keyed other and Ion k*y- UNIT SIZE . 80-82 83-93 PART NUMBER 290351 290352 80-82 290353 83-93 290354 80-82 290355 83-93 290354 80-82 290357 83-93 290358 80-93 290359 80-93 290340 80-93 290341 80-93 290342 80-93 290254 80-82 83-85 84-88 89-91 290030 290031 290032 290343 10-82 290033 13-91 290034 32 00012S s-rv<.*.-* 't1 -!iAmer.:ca*->t^ndard - fOtCtD DZAfT SCOTCH PACKAGE UNIT an 11 ;> L aaeassi^: PARTS DESCRIPTION --Continued DESCRIPTION GAX BOX ASSEMBLY for b#ft driv* burn#rt wirfi Integral psmpi only, IncWlnp p#or bos body, boft, boorinp, pump ond p#ors, oir dodrip Prop, teininp rsnp(i), ilinper, bearing frop(i), fon ktyi ond oil fill cup* Ser. '9291 to 124433 ................. Ser. '24453 ond L*>.................... Ser. Pp291 to '24433................. Ser. '24453end Ufc>.................... All.................................................. UNIT PART SIZE NUMBER 80-82 83-83 86-88 86-88 89-91 89-91 92-93 29X35 29X36 290037 290364 290365 290366 290363 DESCRIPTION SEARINGS Both Endi of Wl FRONT BEARING CAP Direct Drive Burner* All............................... Belt Drive Burner* All............................... Sv. '929I to '24453 Ser.'24453 end Lfc . All............................... UNIT SIZE part number 80-52 290061 B3-P3 290063 83-91 290069 83-91 86-91 86-91 92-93 290070 290371 290070 290371 CEAJt BOX ASSEMBLY for boll d/ivt, purrpltu burner) only. Including poor box body, thoff, boorlngi, cover plot#, oir domper, drip trap, retaining ring(t). having copti), allnger end Ion lieyt. Ser. '9291 to '24433................. Ser. '24453 end th.................... All.................................................. 80-82 83-83 86-91 86-91 92-93 290040 290041 290368 290041 290368 PUMP HOIE COVER for pumpleu poor besot 80-82 29X97 3-93 290098 REAR SEARING CAP Direct ond Sell Drive Burner* Include! Ref. Ring 80-82 290063 83-93 290064 RETAINING RINGS Rev Saving (Tru-Arc) Direct ond Selt'Drlve hr Gev Sox Mlg............................ Direct ond Sell Drive hr Saving Cep Mlg........................ 80-82 29006S 83-93 290066 fXIMAKY AIK DAMfEK Includes plot#, ibeft ond screw*. Diroct Drive Burners........................ Bolt Driv# Burners . 80-82 3-91 0-82 83-93 290043 290044 290045 290046 GEAR BOX BODY With oir donper Diroct Drive Burners Bolt Dr*v# Burners.......................... 80-82 3-91 80-82 83-93 290047 290048 290050 290031 GEAR BOX EXTENSION Bolt Driv# Bum#n........................... 92-93 290369 ROTOR LOCKNUT AND KETEP WASHER Direct Drive Burner*..................... 80-82 83-91 290067 290068 DRIP TRAP 80-82 83-91 92-93 290071 29X72 290073 SHAFT SUNGfR Front I ring Rev Saving .... Direct Drive Only 80-82 83-93 83-91 29X74 29X7S 290076 PUMP DRIVE WORM GEAR ICX OIL FILL CUP Infogrol fvmp Burnon Only . . . . . 80-93 290054 GEAR BOX LUBE (IV GO) Intoprol fump Burners Only. . . 0-93 290055 Integral Pump Burner* Only Three Threod..................... Two Thread................. ... Three Thread..................... PUMP DRIVE GEAR 80-82 83-88 89-93 29X77 290078 29X79 MAIN SHAFT' D>r#ct Driv# Burners Bolt Driv# Burnort Ser. '9291 to '24433 ................. Ser. '24433 ond .................... All..................................... 80-82 83-91 80-82 13-85 86-91 6-91 P2-93 290036 290057 290038 290059 290370 290039 290n et Wee 290077 290078 290078 290079 290080 290081 290062 290063 S3 qs 000126 FORCED DRAFT SCOTCH PACKAGE UNIT PARTS DESCRIPTION--Confinu*d description VISCOSITY VALVE Assembly Six* 80-B2 "H- Models r*qulr* 2902G3 oumbly. UNIT PART SIZE NUM0ER 00-02" 03-05 86-91 92-93 290204 290205 290206 290207 $TTM esimbty Viscosity Volve trvcl^<f*i irtrn, lower ond r*l*f pistons, spot*f, spring ond spring follower. 00-05 290372 86-93 290373 ADJUSTING WHEEL Viscosity Volvo Assembly................. 00-93 290374 SPRING Only Viscosity Vatw* Assembly................. 80-93 290375 DESCRIPTION FITTING - Oil Burn./ Pressure Coupe. Hex Brou with 1/8* N.P.T. topped hot* on lid* lor gouge. N.P.T. T>v*odi. V8" Fm. x V8" Mol* x t-2/4" long ............... ya- Mei. x ya* Moi. * 1-7/8' tong ............................................... 1/2" Mol* < 1/2* Mol* x 2" long 2/4" Mol* x 3/4" Main 2" long UNIT SIZE - 80-02 80-82 83-85 06-93 PART NUMBER 290200 290201 290202 290203 REAR END MODULATING VALVE Assembly Including Plugged Holes for Thermometer ond lubricant 80-88 89-91 92-93 29017? 290178 290180 REPAIR KIT For R*or Fnd Modufoting Volv*. Includes 2 "O" Rings ond 2 Trv/A/c Rings with Instruction*. 80-93 290181 HANO VALVE (SSut-ofO ye- Got vlv............................... 1/2" Gel* Volv*............................... 80-05 290200 86-93 290209 RELIEF VALVE (Adietlobl.) 75* Foctory Sot Six* V4" | 7.5......................................... r i.p.s......................................... 1-1/4" IPS......................................... 26X77 29O210 260004 VACUUM GAUGE (Oil) 0-30- - i-ya- o.d. - i/e- i.p.s. Oil Burner Mounting ....... 80-93 290191 PRESSURE GAUGE (Oil) O-IOOP.S.I. - t-W O.D. l/B" I.P.S. Oil Burner Mounting.............. ... . . 0-200 P.S.I. - 2-1/4" O.D. - 1/4- I.P.S. Oil Pvmp Sot Mountirg.............. 80-93 00-93 291092 291093 FITTING - Oil 8wn* Vacuum Goug*. Hem Vou with 1/8" N.P.T. teppd hel. on tide for gouge. N.P.T. TV*od. V0- F.m. x V0-F.m. . 1-1/2" V8- Mel. x ya- F.m. x 2* long 1/2' Mol. x 1/2" F.m. x 2* long y4- Mol. x 3/4- f.m. X 2" long 00-02 00-02 03-05 06-93 290194 290195 290190 290197 ^ROTARY SEAL Aiwmblp Complete with instruction*.............. 80-93 290182 SWING MANIFOLD 2 Pou Assembly. Includes on* body, 2 nipples end 2 "O" ring. 80-92 290183 83-93 290184 0OOY - (2 Feu Swing Manifold) 80-82 290185 83-93 290186 NIPPLE - (2 Pou Swing Monifold) Top ond 8ottom Nipptos or* otik* Includes on* *0" Ring 80-B2 290187 83-93 290188 -O' RINGS - (2 Pou Swing Monifold) Sol of 2 80-82 290189 83-93 290190 ELECTRIC OIL PREHEATERS AND PARTS HEATER ASSEM8LY Cempl.l. Lou Thermostat end Wiring, Specify voltage. 2500 Worn...................................... 3750 W.m...................................... 5000 Worn...................................... 7500 Won.......................................... lOCOOWom........................... ... 80-02 83-85 86-93 290224 290223 290226 290386 290388 HEATER 0OOY Machined costing ond gasket only. 2500 Wort Six............................. 37S0Watt Size............................ 5000 Wort Six............................. 80-02 83-85 86-93 290227 290228 290228 fi-S 00012V FORCED DRAFT SCOTCH PACKAGE UNIT ^ ^ ^ ^ PARTS DESCRIPTION --Confined DESCRIPTION HEATER COVER Aliembly Includes cover, hlnQe, plot* end body packet. Fop 2500 WoM Heater.................. Fop 3730Wott Heater.................. Fop 5000 Woft HtaNr................. UNIT SIZE 80-82 83-85 86-93 Fee lOOOOWoft Heater..................... PART NUMBER 290229 290230 290231 290389 290390 DESCRIPTION phot shutteT Oil Eurnan Only ...... Oil BURNER LINKAGE SYSTEM Curved >lot rypa. HEATER RODY GASKET When heoter bo* two bodies order one gasket for each body. Fop 2 element Keoier in 290228 bod/ HEATER ELEMENTS 1250 Watts Nominol toting M5 Volt*............................................ 230 Voln................................................ 275 Voln................................................ HEATER THERMOSTAT Dual control ** with thermostat Single control - thermostot only . a THERMOMETER - Oil Temperature Round Dial 1/4" Mala I.P.S. Fen shaped diol * 1/2" Mole I.P.S. for <df burner piping..................... IGNITER AS5EMRLY Includei igniter body or dilei, noxxle, tpvd, clomp, electrode and porcelain and voltage conductor.. Specify typo of gee. PILOT SPUO l.P. Gat.................................................... SCANNER TURE Only Fop Igniter Aisembly . ..................... ... ELECTRODE AND PORCELAIN Fop Igniter Assembly PILOT GUARD Oil burner* Only...................................... The obove tyitem. Include ft>e fallowing pern in the required omounti. 290391 290392 290393 290394 290395 MOTOR MOUNT PLATE For variable fire mo fori . . . . CURVED SLOT ARM 1C Standard (RM) . . ........................ Special (LH).................................. 290234 290235 290836 290396 290397 290238 290237 JACK SHAFT Far Variable Fire Molar Mount Plate 290225 1 Required *................... ... DRIVEN ARM (3-1/4* long) Inetolled on 290406 Jock Shaft and Driven bp Variable Fire Motor I'd Required...................................... DRIVE ARM (1-3/4* Long) Ira tolled on 290406 Jock Shaft to Drive Curved Slot Arm* 2 Required..................................... THRUST REARING For 290406 Jack Shofr - 1/2" Hale ^T^equircd................................ 29CB39 290398 290844 290399 290400 290401 SLEEVE REARING Including Holder end Sere* for Supporting Jock Shaft ^plequired............................................. RAIL AND SOCKET JOINT Angle Type ... A"4. . . , Square Type (Straight) A- 5". CONNECTING ROD 5/16* Diameter, threaded one end 1/4-20. 12 Inch......................... 24 Inch........................... 36 Inch. ........ UNIT PART SIZE NUMBER 290*02 80-82 83-85 86-88 89-93 290*03 290404 290*05 290*06 290255 290257 290407 29 04 08 290256 290413 290*14 290*16 290261 290262 290256 290259 290260 SS A-S 000128 FORCED DRAFT SCOTCH PACKAGE UNIT PARTS DESCRIPTION-Continu.d DISCRETION CUADftANT A55CMUY For Driving Unkog*. Include! on* ttroigHl, on* o*gU boll ond ckt Joint, tcrrwt an4 lode wK*r for ottoching to vlndbe*. UNIT SIZE For 6i**rr Unkep* . . ............................ FART NUMBER 29W17 290418 ADJUSTABIE ANGlt TYPE QUADRANT Uled when neccltery to prtrent troin on boll end >ockl joinn of either pot eolre or blcrwer linkope.............. .................................. 290419 QUADRANT BRACKET-Only For Got Volvo Qvodront ....... For Blower Qvodront........................... For Adjuttoble Anplo Typo Include* Movoble Arm ond Hinpo Bolt, Nun and Waihen . . . . 290420 290421 290422 DISCRETION fUMf A0AFTER Inloprol farl of 290104 ..................... Integral Fort el fumpi 290105 ond 290443 ............................ UNIT PART SIZE NUMBER 13-65 290087 86-93 290068 fUMf SEAL and Cap Gasket fart of fump 290104 ........................ for* of 2901 05 ond 290443 .............. 83-85 290091 86-93 290092 fUMf CAP ond Goikel fart of 290104 Pump......................... Pert al 2901QS ond 290443 .............. 83-85 86-93 290089 290090 GASKET Only for Cap Pori of 2901W Pump........................ Port af 290105 ond 290443 .............. 83-85 290093 86-93 290094 Oil STRAINER, Oil PUMPS AND PARTS A STRAINER Aiiembly Include* body, bosket, outer cap, go*het, Inner cop and lock hondle. RETAINING RING (Tru-Are) Son In groovo in pump shaft behind tool, for* oF 290104 fump . for* el 290105 ond 290443. 83-85 290095 86-93 290096 290100 290101 290102 290444 290445 29044* 290114 ___________________________________________ ____ ____ FORCED DRAFT SCOTCH PACKAGE UNIT PARTS DESCRIPTION --Continued description UNIT PART SIZE NUMBER DESCRIPTION UNIT PART SIZE NUMBER SHEAVE Pwcp Shod) O.D. lor* 12 7/14 10 7/16 12 i/ U 5/8 9 V8 12 V4 Qvi. i ........................ i ......................... 2 ........................ 2 ........................ 2 ........................ 2 ........................ 11 3/4 9 y* 12 1 2 ........................ 2 ........................ 2 ........................ 91 2 ........................ 1I-1C ID 2A 21 2C 3A-4A -48 38-4C X 5A, 51 6A, 68 5C.6C 290117 290451 290113 290119 290120 290121 290122 290123 290452 290453 SHEAVE (Motor Shoft) 5-1/4 in 3-1/4 ys 3-1/4 V4 4-1/4 1/2 4-1/4 5/8 4-1/4 3/4 2-1/4 5/8 2-1/4 V4 2-1/4 7/8 2-3/4 5/8 7-3/4 y4 2-3/4 7/8 1 ........................ II 290454 1 ........................ II 290124 1 ........................ 11 290125 1 ........................ 1C-1D 290455 1 ........................ 1C--1D 290126 1 ........................... 1C-ID 290127 2 ........................ 2A-3A -4A 290130 2 ........................ 2A-3A -4A 290128 2 ........................ 5A-5C 6A-4C 290456 2 ........................... 2I-2C a-x 48 -4C 290131 2 ............................ 28-X a-x 46-< 290129 2 ........................... 58-61 290457 /vfetor ttafl divn*#r dUrmir*i bore of th Ovf. STANDARD *A' GROOVE (1/2' Width) DRIVES SHEAVE (lurrxr Shell) EUc* Cyct* O.D. lor* 50 60 50-60 50-60 2-1/2 3 3 3 V4 V4 V4 3/4 Groove* 2 2 2 3 SHEAVE (Motor SSofi) Cycle 50-60 60 50 60 50 60 50 O.D. Bore Grooves 4 6 7-1/4 6 7-1/4 6 7-1/4 m 2 2 2 3 3 3 3 motor theft diomcrer * 80-82 80-82 83-85 86-93 290160 290161 290161 290163 80-82 83-85 83-85 86-88 86- BS 89-93 B9-93 2901M 290164 290166 290167 290)68 290169 29017C BELTS AND ROPES Cycle Six* 50-60 60 50 60 50 A31 A33 A 35 A34 A36 A3B Jte Rop*. Rop*. Rop*. Rop*. lope. . Rop.- . GATES SUPER "HC" 2V (VS* Width) DRIVES 80-82 83-85 83-85 86-91 86-91 92-93 290172 290173 290174 290175 290176 29046C BELTS O'unp Sol) Soil length Amount R*q 1 46 2 48 1 44 1 44 2 41 2 SO 2 45 2 u 2A-3A 4A-46 1C ID 2*. a. < 2C,X 5A,58, 6A.68 5C.6C 290134 290134 290135 290133 290133 290132 290458 290459 SHE- { (Burner Shoft) E c. Cycle O.D. Bore 60 3 V4 50 2-1/2 V4 60 3-V4- V4 .50 3-1/1 V4 60 3-V4 V4 50 3-1/8 V4 60 3-V4 V4 50 3-1/8 3/4 60 3-1/4 3/4 50 2.8 V4 Groovet 1 1 1 1 2 2 3 3 3 3 80-82 80-82 83-85 83-85 86-88 89-91 89-91 92-93 92-93 290461 290462 290463 290464 290465 290466 290467 290468 290469 290470 57 000130 PARTS DESCRIPTION --Continued * UNIT PAST UNIT PART Of sot IP Tl ON SIZE NUMBER DESCRIPTION SIZE NUMBER GATES SUPER 'HC* IN' (V8* Width) DRIVES (Coni.) SHEAVE (Motor Shaft) 0IRECT DRIVE OIL BURNER MOTORS, 3SOO RPM; 208. 220, or 440vOlf, 3 phot* 60 cycle Cycle 50-60 50-60 50-60 50-60 50-60 0.0. 6 7-1/2 7-1/2 7-1/2 7-1/2 lo't S/8 7/8 1-1/8 1-1/8 1-3/8 &oovi 1 1 2 3 .. 3 80-82 83-85 86-88 89-91 92-93 290471 290472 290473 290474 290473 ROTOR AND STATOR i hr.................................. t-i/2 hr.................................. 3 hr.............................. 3 HP ............................................. 290306 290307 290308 290309 STATOR Only BELTS ("HC" V8") . Cycle Slse 50-60 3V335 .................. 60 3V400 .................. 30 3V375 ................. 30-60 37400 ................. 80-82 83-85 83-85 86-93 290476 290477 290478 290477 \ V9.................................. 290310 1-1/2 hr . .'................................... 290311 3 HP............................................... 290312 i y*............................................... I 290313 PIHtCT DRIVE HUNK MO TO* GEAR BOX ADAPTER & END BEIL Motor Motor Motor Unit Molt* From# hr SilO Adopter End 6*11 fart fort No. Number MOTOR MOUNT PLATE 6elf On'vt 8u*oer. tlofi muff b* drilled or>d topped o moicH mo to* bow hoJei* fiN [Moto* Mount Plate) 80-82 83-91 92-93 290136 290137 290139 L.A. L.A. L.A. U.S. U.S. U.S. U.S. U.S. U.S. 163 203 224 66-5 56-8 203-1 204-2 182 184 1 1-1/2 3 1 1 1-1/2 1-1/2 1-1/2 3-5 80-82 ____ 83-85 . . . 86-88 . . . 80-82 . . . 80-82 . . . 83-83 . . . 83-85 . . . 83-85 . . . 86-91 . . . 290132 290154 290155 290479 290151 290480 290481 290153 290153 290146 290148 290149 290483 290145 290484 290485 290147 290147 Bell Dr*e Burners V3" O.De 1 8" l0O9 e 1/2- O.O. x 9-V8- Long .... 80-82 83-93 290140 290141 MSt MOUNT MOTORS Used on bolt drive oil burners, pump sets end ini*I vortex type forced droft bloweri. Wten ordering any motor, include the following infortnotion from motor to be reploced: 1. Motor Monufoctvser 2. Motor From* 3. htorsepower 4. Operating Voltogd, Phase end Circle 3. lienor Serial Number (Not Motor Seriol Number) If the motor to be replaced it obsolete or unavailable, we will simply the motor we now ore using for tfie tame purpose or promptly recommend the best way so get the burner bock In operation. 1750 RPM-60 cy; 1425 RPM-30 ey. 115 or 230 volt, single phew i/3hr................................ 1/2 tr..................................... V4hT.................................................. 1 HP................................... 1-1/2 hr............................ 2CB, 220 or 440 volt, 3 phoe 1/3 fT........................... 1/2 IT.................. V4HP.......................... i tr.................................... l -1/2 hr........................ 3 HP.......................... 5 hr........................ 7-1/2 HP............................ 11601PM, 7-1/2 IT , 290296 29(897 290487 290299 290300 290488 29(898 290489 290301 290490 290491 290492 290493 290494 SI /J-5 0 00131 3lffc'.t3j^`MCTBaiT7G^'iT*g^^ TORCED DRAFT SCOTCH PACKAGE UNIT, ; ( PARTS DESCRIPTION--Continued DESCRIPTION FLANGE MOUNT MOTORS Used on opposed damper type fvctd draft biowon and *G` vrnen 1750 RPM, 60 cycle 115 or 230 voir, ling!# phase 1 HP.................................. 1-1/5 H> . . . . .................. 206, 270 or 440 volt, 3 phot. 1 ............................................. 1-1/5 bP .................................. 2 HP.................................. 3 HP.................................. 5 HP.................................. 7-1/2 1*.................................. 1160 PPM, 7-1/5 ft.............. Wkft ordering, Include the following information bom starter to b reploced: 1. Starter Manufacturer 2. NEMA Site (00, Oar I) 3. Catalog Nurr&er (On itarter) 4. Overload Hooter Coil Number 5. Vollogo of Magnetic Coil From motor anargiied by itorter: 1. Motor Manufacturer 2. Horsepower 3. Operating Voltoge 4. label Amperage at Oper. Vol t> To further ossure getting o proper re placement, include the burner teriol number (not the motor) ond which motor It controlled by thlt Itorter. Thit might be the oil burner, pump tel or combustion oir blower. If the starter to be replaced it obsolete, we will supply the latest type with the proper overfood pro tection, provided that we fore re ceived the above information, STARTED QvmOAO COILS Supply the tome information ae for motor l ter ten above. Phg. of 2..................................... MAGNETIC CONTACTORS (Used with tome electric oil heotert) 3 Pole - 30Artp. - 110 V - 350 V. Without enclosure - tl5 veil coil , -230 volt coil . With oncleture - )15 volt coil , , . - 230 roll coil , . . When ordering, specify the port number, coil voltoge, heater watts, volts, phase ond burner serioj number. UNIT SIZE PART NUM8ER DESCRIPTION MAGNETIC MOTOR STARTERS NEMA SIZE 00 Includes overlood coils 0 Includes overlood colls 1 Includes overload coils 290495 290496 290497 290498 290499 290500 290501 290502 290503 M-H M93IA MODULATING MOTOR Replocet M904E, Leu trorefofmer ........................... , . , M-H M604C 2-POSITION MOTOR I6(P strobe, leu transformer . 15 second liming........................ 60 second timing ........ M-H AT72 Transformer For M904E, M93IA, M604C ond other 25 volt mofori. Pfote mounting on 4* junction box. AT72DII88, 115 volt.............. AT72DI196, 206 volt.............. AT72DI204, 230 volt............... UNIT PART SIZE NUM5ER 290517 290316 290317 236033 290507 290506 29 0511 290512 29 0513 IOW FIRE START Interlock Switch, adapter, orm ond elec, conduil. For M904E, M931 end M604C SWITCH Only M-H IZE 6-2*0........................ 290514 290516 290318 29031? 290320 290518 290519 RELAYS In Enclosures S.P.S.T. IlSvolt S.P.S.T. 206 vol S.P.S.T. 230volt D;P.D.T. 115 volt D.P.D.T. 206 volt D.P.D.T. 230 volt 290520 290521 290523 290523 290524 290525 IGNITION TRANSFORMER 6000 Volt Secondary* 120 volt, 5Q/60 cy. primary ....... 240 volt, 5Q/60cy. primary........................ 10000 Volt Secondary** 120 volt, 50/60 cy. primery........................ 240 volt, 50/60 cy. primery........................ **eplocet oil 5000 V. front. **For diesel Ignition oil bsenert 290526 290527 290528 290529 WUn orcUrlng, gk* th# burner Uriel I 59 /fS 000132 OUT FORCEO DRAFT SCOTCH PACKAGE UNIT / ?* PARTS DESCRIPTION--Continual 3 yy - n*i DESCRIPTION UNIT SIZE GC L38EI00 AIR-OIL INTERLOCK Mounted on Putnpleis A FIA Isrnen Rang* 2"-l4" W.C.................................... PART NUMBER 290267 GC L38EI0I FORCED DRAFT AIR INTERLOCK (Vorte* Inlet Blewen) Rone* .5'-5.0" W.C................................. 290530 M-H CMSA Pressure Switch Got line Low pressure S.P .D.T. Range 2`-20" W.C..................................... 25*08* M-H C*37G Pruure Switch Opm on Prtuur* Ri** High preub** got interlock Kon(i lU ox............... Ronji .5-5 lb................. 25*077 25*05* W-H C*3/M Prtivr Sv itch Opens low Pi Pan Ror n Preuwte f jII tix* Go* l/.'erlock t-)6oz............... .5-5 ib................ 25*076 25*053 H*. SAIL ? 7lT_CH foie*'-* Droll AIr li kIocJc (C?fC. .d dcr.^f ' iowP). M-H l*C:~C Fir t 5wi7;b Mom j( Ke+e*. O. in on Tit^ retvf* *i# c 'ey*' \t$c 290531 25*063 UNIT ___________ DESCRIPTION________________ SIZE G<K\>W Volv Main oil krnor fuel oil tbwl-off, (Glow Wound Coll) Comp|i Volvo - 120 Volt..................... Replacement Coil Only - 120 Volt * . . Complete Volvo - 206 Volt Replacement Coll Only 206 Volt . * . Complete Volvo - 2*0 Volt..................... Replacement Coil Only-2*0 Volt , . . Union Ga*ltl Only G< K)0-1/2" Volv 100 G*P*K. ond larger oil burnor Mein *bvl-off volv* (Glof* wound coil) Complete Volvo - 120 Volt .................. Replacement Coil Only - 120 Volt , , * Complete Volvo - 206 Volt Replacement Coil Only - 206 Volt * * Comploto Volvo - 2*0 Volt..................... Rep focement Coil Only - 2*0 Volt ... Union Gofctt Only M-H V*001-A Oil Volvo Ditsol Ignition, Doloyod Opening 120 Volt........................................................ 206 VoJt......................................................... MAXITRQl RV-42 Pilot Got Prciiur* Regulator with Adj. HO,l (Hue) Spring 4--12' W.C For 2 ps! or under got supply . .... FISRBU5231-4___________ Pilot Gos Pressure Regulator Adjustable 5-I/4--9-1/4- W.C. For over 2 psi got supply............................ PART NUMBER 290276 29 0282 290277 290283 290278 290284 290283 290279 290283 290280 290286 290081 290287 290089 263625 263626 263627 29QJ32 M-H V*93 Go* Pilot Volvo I.P., Notvrol of Mfg* Go Coftyjlat* Volv* - 120 Volt Replacement Coil ON/ * 120 Volt Cor-pUt* Volvo - 2*0 Volt Replacement Coll Only - 2*0 Volt 263316 290274 263317 290273 MAIN GAS BURNER VALVES A REGULATORS Con toet the factory, supplying oil pertinent Information such os: 1. Burner serial number 2. Manufacturer of Item 3. Catalog number from li>el 4. Voltage on label 5. Pip* size A. Appmesit trouble 206348 206538 TVn.Ti SltYi4>--..V nvrl I v7r^^^rr^mn^ me -m.-^ _-. . FORCED DRAFT SCOTCH PACKAGE UNIT, PARTS DESCRIPTION--Continued DESCRIPTION FIREYE 2MJS Programming Control Chaufi Only Model 60! B..................................... Model 4008 ..................................... UNIT SIZE PART NUMBER 204431 204539 FIREYE 48PTI Seonner Only..................... 254000 CABINET Only for 26RJ8........................... MOUNTING FRAME Only for [rwtoffing 76RJB infkg. Control Cobtruh................. VACUUM TUBES, ETC. Only Model 6018 ored 60C6 J2AX7.............................. ... e e , 17RW7A.................................... ... 6 Amp, Tjrpe SAG Fiu................... For Scanner iflPTl M-H JU78A Froteetoreloy Chouls with Tubes Only................... VACUUM TUBES Only Groy Model R478A M-H '102988 (3 Req.)....................... M-H '107303(1 Req.)....................... Golden Model X47SA M-H *IU*24 (1 Icq.)...................* M-H '102988 (1 Req.)..................... M-H H478B Protec tore) oy Chouit with Tubes Only..................... 204542 204544 257161 257170 215193 204024 2511)2 257142 257200 257143 257142 251111 DESCRIPTION MANUAL POTENTIOMETER For Manuel Poiliiening of Molar Controlled Fira Six* Potentiometer........................ Dial Plelo............................... Pointer Knob........................... ItElAYS - 25 Amp., 113/230V. S .P.D.T. 115 Volt Coil . . . S.P.D.T. 230 Volt Coil . . . D .P.D.T. 113 Volt Coil . . . D .P.D.T. 230 VollCell . . . D.f .S.T. 113 Volt Coll . . . D.P.S.T. 230 Voll Coil . . . INDICATING LIGHTS Socket Only..................... Lamp Only Lora Only (Specify Color) Complete Assembly .... When ordering. Include the following Informotion, 1. Burner Serial Number. 2. Type of Lamp - Neon er Incandescent 3. Control Voltage LABELS (Plastic) Engraved White on Block Background 3" *6`........................ V4-k2`........................ Include the required wording of the label In the order. VACUUM TUBES Only Groy Model R4788 M-H '102988 (2 Req.)....................... M-H '107303 (2 Req.)....................... M-H '106408 (1 Req.)..................... M-H '100448 (1 Req.)..................... Golden Model R4788 M-H '114424 (1 Req.)..................... M-H '110969 (1 Req.)..................... M-H '100448(1 Req.)..................... FUEL SELECTOR Toggle Switch Stops ot center^ff. Mh*t be releoeed ond pressed again to continue three to other fuel position. SArrp., 240 V. - 10 Amp., 120 V. 2 P.D.T.......................................... . 3 p 0 T.............................................. 4 P.D.T.............................................. 257162 257200 257201 257161 257143 257144 257141 GAS MANIFOLD ASSEMBLY Includes Manifold, Refractory, Vones, Spud Nipples end C^s, Plastic Cone, Asbestos Tadpole Pocking ortd Pocking Clomp GAS MANIFOLD Includes oil Ports Which Are Welded Together, With Drilled end Topped holes 290554 290555 290554 VANE ASSEMBLY For Go Monifold UNIT PART SIZE NUMB EH 290248/^ 290637 290338 290559 29 0540 290541 290542 290543 290544 290243 290244 290265 290244 290545 290544 BO-82 83-85 84-88 89-91 92-93 290437 290438 290639 290440 290641 80-82 83-83 84-88 89-91 92-93 290442 290443 290444 290445 290444 80-82 83-83 84-88 89-91 92-93 290447 290448 290449 290450 290651 ^50 0013'l FORCED DRAFT SCOTCH PACKAGE UNIT PARTS DESCRIPTION--Continued DESCRIPTION SPUD NIPPLES 1/4" N.P.r. Both Endi 3'....................................................... 3-1/2"................................................. ............................................................. 4-1/2" ................................................. 3"....................................................... 5-1/2"................................................. ............................................................. 6-1/2"................................................. UNIT SIZE PART NUMBER 290652 290653 290654 290655 290656 290657 290658 290659 SPUD CAPS Drilled po Petition, Angle and Pori Six* os Jndieoted Oft Foctory Record. If Complete Set it Not Required, the Qty. Dr*d for Eoch Row (Outer, Inner or Middle) Must be Shown on Order Drilled Eoch...................................... Blonk Eoch................................* . . PLASTIC CONES, ASBESTOS TADPOLE PACKING, PACKING CLAMP AND TILE DOOR CLAMPS ARE LISTED ON PAGE 52 290660 290661 The fottowiM pt* or* for blower* who** etr delivery T* controlled by th* oopoted two domper qur mbly In the duct connecting the blower to ths wirdbox Piece# supply ths burner (no) ths motor) teriof number BLOWER BLOWER DAMPER LINK ASSEMBLY SIZE Includes four dcmoec ormi with 7/ 290423 set screw*, two connecting end f 290424 on* reversing link*, oil riveted together. 1 1/ 1 1/2 290425 290426 Damper BLADES (4 Rreuirod) Eoch 7/* 1 1 1/8 1 1/2 290427 290423 290429 2904X DESCRIPTION SLOWER ADAPTER ASSEM8LY (Oppettd Deeper Typ) IneludM Hooting/ Oompef Blades, Rod*, Link Ajisihbty, end oil Scrwi, Nut*, Wodsn end Clomp* for Attaching to Blower end Windboa* SLOWER ADAPTER HOUSING (Opposed Dorrper Type) Welded Asiembly Only BLOWER ASSEMBLY (Oppoted Dove Typo) With Air Dorrpert In Duct ot Blower Outlet, Include* Homing, Wheel,.Inlet Ring, Inlet Screen, Screen Clomp*, Clomp Spocrre, Mow Adopter end Ftonge Mount Motor, *7/8 Blower *7/8 Blower *1 Slower P| -1/8 Slower *1-1/8 Hewer *1-1/2 Blower 1-1/2 Mow 2 HP Motor 3 W Mow 3 t* Motor 7-1/2 rt> Motor 7-1/2 hP Motor BLOWER WHEEL ONLY (Oppoted Oompor Typo) Internol Hub, C.W. Rototienwith Bore oi Specified in Order or From Foe tery Record Slxo *7/8..................................... Size *1 ........................................ Slxo *1-1/8.................................. Si to *1-1/2.................................. UNIT PART SIZE NUMBER 10-82 83-85 86-87 88 89-91 92-93 290567 290568 290569 290570 290571 290572 60-62 B3-B5 86-87 88 $9-91 92-93 290573 290574 290573 290576 290577 290578 80-82 83-85 86-87 88-89 90-91 92-93 290587 290588 290589 290590 290591 290592 80-85 86-87 88-91 92-93 290593 290594 290595 290596 DAMPER SLADE RODS (V8" Ola.) Short Rods (3 Req.) Eoch Long tod (1 Req.) 7/B i 1 1/8 1 1/2 1 1 1/8 l 1/2 DAMPER BLADE CLAMPS 3/4" OD > 1/2" ID Coder WiA tel Vrw-.................................................... 290431 290432 290433 290434 290435 290436 290437 290436 290439 INLET RING Only (Oppoted Denver Type) Slower Size *7/8........................ Slower Six* *1 ........................... Slower Size *1-1/8.................... Blower Size *1*1/2.................... 80-85 86-87 88-91 92-93 290601 290602 290603 290604 INLET SCREEN Only (Oppoted Oomper Two) Blower Site *7/8 Slower Size *1 ........................... Slower Size *1-1/8..................... 80-85 86-87 88-91 92-93 2906OS 290606 2906a 29O6C0 *2 ^00013* 1 1 i ii ( FORCED DRAFT SCOTCH PACKAGE UNIT PARTS DESCRIPTION --Continued DESCRIPTION MOTOR ADAPTER Only (Oppottrf Dofnp*f Typ.) '7/8 Blow.r J-l/5 t 2 W 'l Blower MoIor , . . , 3 HP Motor. , , 'l-l/l lowr S KF Motor . , , Fl -- 1/S Blow.r 7- 1/2 FF Motor '1-1/2 Blow.r 7-1/2 hF Mo For UNIT 9AXT SIZE numier 80-85 64-87 68-90 91 92-9J 290609 290610 290611 290612 290613 SCREEN CLAMPS Only (Opposed Domper Type) All Blower Sizes - EocH 290616 CLAMP SPACERS Only (Opposed Domper Type) All Blower Sizes - Eoch BLOWER HOUSING Only For All Blower Assembly Types Nomine! Size *7/8.............. Nomlnol Size *1 ................. Nominol Size *1-1/8 .... Nominol Size *1-1/2 .... BLOWER ASSEMBLY (Vortex Type) With Air Domperi of Blower Inlet. Includes Homing, Wheel, Vortex Domper Assembly, Screen. Foot, Motor Fforform end Foot Mount Motor. 290615 80-85 86-87 88-91 92-93 290621 290622 290623 290624 80-82 83-85 86-87 88-90 91 92-93 290662 290663 290664 290665 290666 290667 DESCRIPTION BLOWER WHEEL Only p/orf* Typt) Externol Hub, C.C.W, Rotolion Wirf Bore Specified In Order or From Foctory Record. Nominol Site *1/8 ....... Nominol Size *1 ........ Nominol Size *1-1/8 ...... Nominol Size *1-1/3 ...... VORTEX DAMPER Aiwmfely Nominol Size *7/8.................... Nominol Size *1 ........ Nominol Size *1-1/8.................. Nominal Size *1-1/2 ...... UNIT FART SIZE NUMBER 80-85 86-B7 88-91 92-93 290617 290618 290619 290620 80-85 86-87 88-91 92-93 290625 290626 290627 290628 VORTEX SCREEN Nominal Size *7/8 ....... Nominal Size *1 ........ Nominol Size *1-1/8 .................. 80-85 86-87 88-91 92-93 290629 290630 290631 290632 HOUSING FOOT Only Vert.. 516. Nominal Size *7/8.................... Nominal Size *1 ................. Nominol Size *1-1/8 ....... Nominol Size *1-1/2................. 80-85 86-87 88-91 92-93 290633 290634 290635 290636 BLOWER ADAPTER (Vortex Type Slower) 80-82 83-85 86-87 88 89-90 91 92-93 290579 290580 290581 290582 290583 290584 290585 <3 000136 LJ i \ CHAPTER 7 MANUFACTURERS DATA This section of the monuol contain! moteriol from monufocturer's literature which explains in detail the opplicotion,.mointenance ond service of various components used In stondord Kewanee units. You may wish to insert additional data sheets for other controls included with your boiler unit. This manual, ond manufacturer's literature on other boiler room equipment, should be kept for use as a complete source of reference material for maintenance and service. 65 /& 00013 8 } I i H INSTRUCTIONS KJimnu Minneapolis - Honeywell Regulator Company MINNIM01IS I, MINHIJOTA TOtOHTO V, 0NMII0 r R478B FLAME SAFEGUARD RELAY APPLICATION The R478B If an electronic flame-safeguard and programming control for commercial and tnduetrtal application on gas, oil, and combination gas*oll burn ers and burner*bol)er units. It Is used with a flamefllcker type (lead-eulflde cell) flame detector and. also has provisions for using a flame rod to prove the pilot. FEATURES SAFE-START CHECK: Prevents starling the burner and causes safety-switch lockout If the flame de tector senses an actual flame or a flame-simulating component failure exists In the electronic network at any time during a burner-off period, PREPURGE: 30 seconds fixed; or 1 or 3 minutes, field-selectable. POSTPURGE: 20 seconds. TIMED IGNITION: 2 selectable trial - for - Ignition timings on each of two models: 15or SO seconds on 30-second-prepurge model; IS or 30 seconds on the other. INTERMITTENT OR INTERRUPTED PILOT: Fleldselectable. COMPLETE FLAME SUPERVISION: Pilot and main flame, or malnflame only, field selectable. Flame rod may be used to prove gas pilot only. SPECIFICATIONS-------------------------- MODEL: R478B Flams Safeguard Relay. Use with flame-flicker type (lead-sulflde photocell) flame detector. (Flame rod may alio be used to prove pilot.) VOLTAGE AND FREQUENCY. 120, 208, and 240 volts, 80-cycle model standard. A 50-cycle 120-, 2C8-, and 240-volt model is available. Both mod els have a selectable-voltage link which permits CUTOFF OF FUEL: On loss of flame. RAPID FLAME RESPONSE: Cuts otf fuel In 2 to 4 seconds on loss of flame. SAFETY-SWITCH LOCXOUT: On loss of flame, fail ure to Ignite, or electronic-component failure; 15second timing. FIRING-RATE OPTIONS: On-off, high-low, or mod ulating, field-selectable. Return to high fire after fuel valve opens or after Ignition period, fieldselectable at R478 terminals. INTERLOCK TERMINALS: Provide for separate safestirtlng and running Interlocks. ALARM TERMINAL: Powered to operate an external alarm when safety-rwltch lockout occurs. SEQUENCE INDICATING LAMPS: Three neon lamps Indicate PREPURGE-POSTPURGE, PILOT and IGNITION, and FLAME - PROVEN, respectively. their use on 120, 208, or 240 volts. ELECTRICAL RATINGS OF TERMINALS: 120 to 240 volts. Ignition (Terminal S).............................. 300 VA Pilot valve (Terminal 5 or7)... . 70 VA Main fuel valve, gas (Terminal 8) . . 120 VA Main fuel valve, oil direct Ignition (Terminal 7).........................................70 VA Fig. 1 -- Installalien dlmenttona -- Q2HA and Q407A Cabinets and Q2SSA Panel. 67 000140 Alans contact (Terminal 9) . , . Flam* modulating control (Terminate 10, 11, 12, and 13)..................... Burner Motor (Terminal I); cabinet Cabinet or panel must be ordered sepa rately. Bet Fig. 1. VACUUM TUBES: (replaceable See Ftg. 11, for tube localtons. Tl--Part No. 114624 (8007) Voltage Full Load Locked Rotor T2--Part No. 110969 (SMS) Amperes Amperes T3--Part No. 100666 (12AX7) --no------ 31.3 OPTIONAL SPECIFICATIONS: Specify one. 1I 206 3.7 240 3.7 22.2 22.3 1. 30-second prepurgs, field-selectable 15- or 60-second Ignition timing, and 15-second saftly-swlleb timing. POWER CONSUMPTION; 41 watts maximum; 13 2. Field-selectable l-or-3-mlnute prepurge, 15- watts standby. MAXIMUM AMBIENT TEMPERATURE; 60-cycla, or 30-second Ignition timing, end 15-second safety-rwiteb timing. 115 T; 50-cycle, 100 F. DIMENSIONS See Fig. 1 for separatepanelaad cabi ORDERING INFORMATION: Specify -- net dimensions. 1. Model number. i MOUNTING: Q294A surface-mounting dust-rest slant cabinet; Q295A panel for installation in suitable enclosure; or Q407Aflusb-mountlng dust-resistant 2. Voltage and frequency. 3. Timing combination. 4. Cabinet or panel. If required. INSTALLATION----------------------- Applicable Installation Instructions provided by the burner manufscturer should be used In addition to tbs 1 corresponding instructions given here. Tbe checkout i procedures on this sheet, end any others recommended by tbe burner manufacturer, should be used to perform s thorough operational cheek of the Installation before putting tbs system Into service. ri**t oitccio* (icc r.si FLAME DETECTOR Proper flams detector Installation is the basts of a good flame-safeguard Installation. Refer to the In structions packed with the flame detector and to the burner manufacturer's Instructions. Follow instruc \ tions carefully to make the best possible application of tbe flame detector. HLMH Hnownwr rant St>SSw}<--f f-ovroi nuo. Atosrrcmwroranrv-- tsnt.owcrv 00*mca.vrTCianc*-r j PANEL OR CABINET Fig. 2 -- Basic R47SB hookup. See also Fig. 3, 4, 3 and 6. 1. locate tbe cabinet or panel where the sur rounding temperature does not exceed 113 F for 60cycle model, or 100 F for 50-cycle model. 2. The back of the panel or cabinet must be moun ted vertical. 3. Be sure to allow clearances for servicing and for removal of the relay chassis. fTATICN- HOT LB wm - w- r.--n _m_t_ld_K_iiTt" xzj {D A WIRING See also, TIMING ADJUSTMENTS. 1. All wiring must comply with applicable elec trical codes, including use of NEC Class 1 wiring. 2. Refer to Figs. 3-6 sad Ftg. 13 for typlcsl wir ing diagrams; but follow tbs burner manufacturer's wiring diagrams, if provided. 3. Add required disconnecting means and over load protection to power supply circuit. 4. Wiring circuits should be checked with a bell or lamp before tbe R47I ehaasts ts Installed. MANUAL 1TAAT "TrC6r*LMI--MT-I**TrQJ|t WBMIWWlIoMr.? I| ' . i" If 'e*--- m INTlAOCtlA) ta _____r fe AUTOMATIC 1TAAT mmm Fig. 3 -- Starting circuits -- manual sad automatic start. ) CHASSIS VOLTAGE SETTINC: The R478 can be *et lor any one of the thre* common -e line-voltage upplle-- 120, 208, or 240. Set the dju*Ub!e link to match the *uppty voltage: 1. Looeen the center *crcw (Fig. 7). 2. Remo** the end (crew*, rotate the link to the proper voltage, then iniert the end (crew*. 3. Tighten all three (crew*. Fig. 4 -- Firing-rate control*. ROB provide* only rwltcblng (or *cparatc flrlng-rale control*. PM*4K0ota Fig. 7 -- Adjustable voltage link. (On back of cha**l(.) INSTALLING CHASSIS: (See Fig. 8.) 1. Open the *y*tem dlaconnect ewltch. 2. Insert the chassl* ear* Into the tockel* located above and below the terminal (trip of the panel or cabinet. Prei* the chassl* Inward firmly Into place. 3. Tighten the large clotted-head retaining *crtw near the chassis handle. 4. Looeen the relay cover retaining (crew* and remove the cover. 5. Remove the cardboard packing Insert* and REPLACE THE COVER. mi nAvtawAA* rwaurm irm mtm n-im) " F f r (Miri r- Fig. < -- riimt detector eonnecttoa* to R47BB. Fig. 8 -- Installing cbasal* (bottom view with cabinet cut away). fl-j 00014 2 timing adjustments IGNITION: Inatall or remove Jumper at terminals M anl IS, u shown. ' The meter reading may drop but the FLAME-PROVEN lamp ahoold remain lighted. U the reading drope be low 90 toIU, or the FLAM!-PROYEN light goce out, reelght photocell and than reteet. Reconnect 17-G Jumper. M M MKMMOOCk PREPURGE: (l-or-3 minute model only) Xrjtill or remove the Jumper between terminal* 14 and G, u ehcrvn. Thl* adjustment doei not apply to the 30-seeond-prtpurg* model. FVt'UMI T1KC I lliNVTf TIMC 1 MlNUTCt CHECKOUT TO CONTROL SEQUENCE MANUALLY ' REMOVE TOP VACUUM TUBE T1 (114924) TO KEEP THE R47SB ON CONTINUOUS PRSPURGE WHILE CLEARING FUEL LINES OF AIR. TOKEEP PILOT ON CONTINUOUSLTDURING PILOT CHECKOUT, REMOVE TOP VACUUM TUBE T1 AND DISCONNECT MAIN-FUEL VALVE WIRE FROM TERMINAL 9. PRELIMINARY INSPECTION: 1. Power on at ayitem-dlaeonnect retteh. 2. Wiring connectlone correct and tight. 3. Vacuum tubee eeeure In socket*. 4. Flame-detector Installation completed. 5. Burner completely Installed and ready to fire; fuel lines purged of air. 9. Combustion chamber and flues claar of fuaL THEN MAKE ALL OF THE FOLLOWING TESTS. MAIN-FLAME PHOTOCELL CHECKOUT. Use only a lead-sulfide, Game-Dicker-type call such aa the C701SA. Taat the installation thoroughly before the system is put Into operation. Photocell performance la affected by. 1. Position, else, and burning characteristics of the flame. 2. Hot refractory. 3. Ambient temperature at pbotocelL (Check In structions packed with flame detector.) To teat photocell output, run the burner at high .fire with Jumper 17-0 In place. Then plug In the volt meter as shown In Fig, 9 The meter reading abould be between 100 and 140 volts. With the meter plugged In, remove 17-0 Jumper. Pig. 9 -- Voltmeter connectlone for teitlng the tead-eulflde photocelL If the C701SA la also need to prove that the pilot Came la capable of lighting the main burner, make the following pilot turndown teat. PILOT TURNDOWN: Teat to males certain that the main burner can be Ignited by the emalleet pilot flame that will prevent relay 2 from dropping out (or FLAME-PROVEN light from going out). 1. Remove vacuum tube Tl. 2. Remove the main-valve wire from terminal 6. 3. Remove any'modulating control wire from ter minal 12, to keep the firing rate at low fire. 4. Turn on the power, open the manual fuel valves, and start tho system. Relay 1 should pull la and the PURGE lamp should light. 5. Push in relay 3 manually. PILOT - IGNITION lamp should light, pilot should light, relay 2 should pull in, and ths FLAME-PROVEN lamp should light. 9. Turn ths pilot down very slowly, stopping In stantly when relay 2 drope out end the FLAMEPROVEN light goes out. 7. Turn up pilot slowly until FLAME-PROVEN lamp Just lights. I. Quickly touch the main-valve wire to terminal 9. This should cause ths main burner to light Imme diately. B It doss not, remove ths wire from termi nal I it once. Than relocate or reposition ths flams detector so that relay ] will drop out and FLAMEPROVEN light wtll go oui before tbs pilot Cams be comes too small to light ths main burner. This usually requires r(sighting or relocating tbs flams detector farther out along the axle of the pilot flame toward the mala flame. See also tbs Instructions packed with ths flams detector. NOTE: Ths safety switch will trip, causing relays 1 sad 3 to drop out and shut off tho pilot light about IS seconds after relay 2 drops out. if this occurs before the main valve wire le touched to terminal 7, It wtll be necessary 70 000143 to watt Imlnulea for the saftty-rvltch beater to cool, then reeet thia switch, reetart the a yetem, and again push In relay 3 manually before repeating alep T. B. Repeal the testing and adjusting until It has been definitely determ Laid that the mala burner will posi tively be lighted with the pilot flame Just large enough to katp FLAMR-PROVJOf lamp lighted. Repeat the lighting eereral Uaea with the pilot flame at thle tun* doena polal to make aura. 9. Wbea thia teat baa beea completed, tun off the power, reconnect the wlrea to tbelr original tarml- aala, aid replace vacuum tube Tl. Turn the pilot flame back up to normal. NOT*; Repeat ALL flame-detector teete after ALL adjustment* hare beea completed. ALL teete muet be aatlafltd at the FINAL Damedetector poetttoa. e. Bee at the aafety awtlch U open. <L Start the ayatem. PURGI and PILOT IGNITION lamp* light. a. Pilot will not light. FLAMX-PBOVZN lamp doea not light. The aafaty awttch ahould trip and lock out about IB aeeooda attar atarttng the ayatem. Alarm ahould sound, If uaed. railore to Light Mala Flame a. Turn on the fuel eupply to the pilot burner only, leave main-burner fuel aupply abut oil. b. React the aafety awttch. c. Start the ayatem. d. FLAME-PROVEN lamp ahould glow and pilot should light, but mala burner wtu not light. Relay 3 should drop out and FLAMX-PROVXN lamp should go out within 2 to f second* after PILOT-IGNTTION light goes out; tha aafety switch ahould trip and lock out about IS * recede later. PILOT-FLAME-CIRCUIT TEST; If a flame rod la uaed to prove the pilot, a mini mum current of 2 microampere* ahould flow lu the pilot Dame-detector circuit wbea the flame rod la properly Installed and poattloaed with reapeet to the [u pilot Came. Thle may be checked with aa ac curate d-c mlcreaameter (aee Tig. 10). A current ol lest than 2 mtcroamperea tadteatea Improper la lallatloa or aome other defect la the circuit (laaufflclent ground. Improper detector poetttoa, poorly conducting flame, etc.) and muet be corrected. After a current of at leaat 2 mtcroamperea ta aaauxed, make the pilot turndown teat daecrtbed above. Hot-Refractory Hold-In: Teat to make certain that the hot refractory will not cauaa relay 2 to remain In at the end of a normal run; thle would cauae aafetyvwUcb lockout. Operate the burner until the refractory reaches ILa maximum temperature, than uaa the controller to atop the buner. Relay 2 ahould drop out (d-c volt meter reading ahould drop to tero) within 2 to daacaods later; tf It doer not, the photocell may be affected by the hot refractory. Relight the photocell at a part of the flame haring a cooler and/or more dlrtant refrac tory background. Ccatlnueto teat and adjurt until hotrefractory hold-In te eliminated. Tor more Infor mation on C7015A (formerly Q283A) refer to Form 9S-2123. SAFKTT LOCKOUT Safety lockout ahould occur upon failure to Ignite the ptlot, upon failure to light the mala burner, and upon loaa of flame. Check each of theee eondlttona aa followa. Failure to Ignite Pilot a. Shut off the fuel eupply to both pilot and main burner. b. Turn on the electricity. Loaa of Flams a. Turn on the fuel aupply to the main burner; pilot gxs aupply also must be on. b. Reset tha aafaty switch. c. Start tha ayatem. Start-up ahould be normal and mala burner ahould light at end of normal prepurge period. d. Shut oft the mata-burner fuel supply to extin guish the mala flame. c. Relay 2 ahould drop out within 2 to 4 seconds later, and the FLAME-PROVEN light ehould go out. L The aafaty awttch ahould trip and lock out about 15 aceoada after FLAME-PROVEN light goes out. NOTE: If the aafety rwltch falls to lock out and shut down the .system on any of these three teats, replac* the R418B with a new one; then rerun all CHECKOUT testa from tha beginning. aceoiaxita Fig. 10 -- Mtcroammeter connections for tha flame-rod circuit. 71 ^000144 OPERATION ------------------------------- See Dr- 11 for rclaj and vacuum tube location*. Sea Flj. 12 tor a ecbematlc wiring dlafram of the JU7SB, Including a typical bursar circuit. NORMAL OPERATING SEQUENCE The normal operating sequence of the R47SB la aa follow*. power or7 Qitir* *7item la da-energized POWER ON Vacuum tuba* T2 and TJ heat, flani relay 2R may pull In and blatantly drop out, due to a voltage rurf* la the electrode network. Component check begins. (Sew p. 7.) MMaa uj** m FIf. 11 -- R478B with cortr remortd. A Jumper between terminal* H and IS provkUa lSitcond Ignition tlmlnr, no Jumper, JO- or 60aacood timing, aa apact/led on ordar. Flf. 12 -- Schematic of typical burner ayatam Including tha R47SBL /j-J 00014 5 I f i i i a s i j i i & i s f e i i s s-l-s-a STARTING (Controller call* for heat, or START buttoo L depressed momentarily then releaaed.) PURGE limp light*. Relay 1 pull* la. Powers tirmlail S. Burner motor start*. Pripirp begin*. 7rspurge timing begins. PILOT-IGNITION limp light* after 30 (*00041 (or 1 or 3 minute*, depending eo model nod liming jumper). Relay 3 pull* In. Power* terminal* I and T. Safety-switch healer 1* energized. Ignition transformer li energized. Pilot valr* or let-ilnge oil relr* open*. WHEN ELAMS IS PROVEN 7LAMS-PROVEN limp light*. Relip 3 pull* la. Power* terminal 8. Kata gu rale* or oil valve open*. Opeaa circuit between terminal* 12 and 13. Cloece circuit between terminal* 12 and 11. High firing or modulating tiring begin* It con nected to terminal 11. PILOT-IGNmON light goe* out. Relax 4 pull* In. Dt-energize* terminal 8. Interrupted pilot ralre cloeee, it used. De-eaerflaes lgoltloo braneformer. Cloeee circuit between terminate 10 and 12. High firing or modulating firing begin* if con nected to terminal 12. Optna clreult to terminal P. STOPPING (Controller caotact* open when beat demand SERVICE--------------------------------------- SCHEDULED INSPECTION AND MAINTENANCE A acbedule should be set op and followed for peri odic Inspection and maintenance. Including burner and all other controls a* well ae the R478B relax. Include the following In that schedule. 1. Keep burner(s) and fuel mixture always ad justed according to tb* burner manufacturer's recom mendation*. 2. Clean tb* photocell len* and night tube, nod check the photocell output. See subject MAIN-FLAMS PHOTOCELL CHECKOUT. 3. If n dame-rod dam* detector ts used to pror* pilot dame, check the dam* rod and tin output. 4. Install a new net of Taciturn tube* every pear. NOTE: Keep the R478B powered the year around except while servicing, to present conden sation -wtthtn the cabinet. TROUBLE SHOOTING Brerx trouble-!hooting job should not only result la locating and correcting the Immediate can** of trouble but should Include an orer-al] check sufficient to assure continuing good performance. Erery le MtiafleJ, or STOP button Is deyrmed momentarily then released.) FLAME-PROVEN light goes out. Relay 1 drop* out. Dt-en*rglxee terminal* 6 and T. All fuel ralre* clot*. Poftpurg* begin*. Relay 2 drop* out. Open* circuit between terminal 12 and terml nil* 10 and 11, Cloae* circuit between terminal* 12 and 13. Relay 4 drop* out at cod of 20-aecond pos'.purgi tlnlaf* Cloaca circuit to terminal F. Relay 3 drops out. De-energtxes terminal 8. Burner motor stops. PURGE Light goe* out. Normal cycle coda. ELECTRONIC-COMPONENT CHECKS The electronic network. Including the Qxme-detec tor circuit, t* designed eo that component failure either block the starting circuit completely, or eauesafety-rwltch lockout and atop the sequence during th< prepurge period. 1. If relay 21* held In or caused to pull In (because of a component failure) during a bumer-otf period aafety-rwltch lockout occur* and the ayttem cannot bre-started until manually reset. 2. If relay 4 doe* not operate during a itart, th. sequence cannot proceed past prepurge. 3. If relay 4 does not drop out (stick* dosed) Im mediately after relay 3 pull* In during a normal start the Ignition cannot come on; prepurge continue* untl afety-rwttch lockout Occur* about IS second* later trouble-shooting job should begin wtth a recheck ofal item* listed under subject SCHEDULED INSPECTION AND MAINTENANCE. Then if trouble still persists, the next step It t determine whether the trable Is In the R47IB or else where. Review the normal operating sequence of th R4788 a* given under subject OPERATION. Then ebee th* actual operation against th* normal sequence t de'ermtn* how far through th* sequence the R47S: perl' as normally. Knowing th* stage t! which th P*r<-, mane* deviate* from normal will help In locattn th trouble. CHECKING PROCEDURE Close the starting circuit by pressing the START button, or by raising the controller setting high enough to dose th* controller contacts. A. If R478B WILL NOT START OPERATING SEQUENCE, check the following: 1. Make sort that the voltage selector on bsck of chassis ts correctly set for the rdtage supplied at terminals 1 and 2. 2. Reset th* safety switch If it l* open. 73 /?j 00 014 G v- ' *4 a. If switch cannot be reset, tt probably In dicates that relay 2 t< botdtng La (FLAME-PROVEN lamplighted) because of aflame-slmulattngcomponsnt iaUara. (]} Change ntuiD tubes T2 and TJ. If till docs aot alto* nitty switch to be rant, remove vlrts from terminals PC and 0. (a) It Oats allowi ralay 3 to drop out, trouble la outalda the R478B and la In the photocell circuit. (b) It this does sot allow relay 3 to drop out, replace the R478B with a new one. 3. Jumper terminal! 1 and 4. a. It PURGE lamp then lights and burner motor (tarta, the trouble ta outflde the R478B and la In the limit circuit or the controller circuit. (1) Remove the 1 - 4 Jumper. (2) Jumper the limit circuit and the con troller circuit, In turn, to discover the one that ta open. b. It PURGE lamp does not ll|ht and burner motor does aot atari when terminals 1 and 4 are Jump ered, remove Jumper; then Jumper terminals 3 and 4. (1) It PURGE lamp then lights and burner motor starts, the trouble te outside the R473B and la In the starting Interlocks). (a) Remove the 3-4 Jumper. (b) Using burner or boiler manufac turer's wiring diagram as a guide, Jumper each start ing Interlock, In turn, to discover which one la open. (2) It PURGE lamp does not light and burner motor doea not start when terminals 3 and 4 are Jumpered, the trouble la inside the R47SB. (a) Loosen the relay cover retaining screws and remove the cover. (b) Clean the contacts of relay 3 as described under subject CLEANING CONTACTS. (c) Replace the relay cover and tighten the retaining screws. (d) It trouble sltll persists, replace the R478B with a new one. B. It R478B WILL NOT PROGRAM, check the fol lowing: 1. 1/ PURGE lamp lights but burner motor and/ or dratt fans do not run, the trouble Is outside the R478B. a. Check motor power supply. b. Check motor overload protection. c. Check motor (tarter d. Check motor. 2. It programming will not go beyond prepurge: a. Clean all relay contacts as described under subject CLEANING CONTACTS. b. Install a new 11 *424 (Tl) vacuum tube. c. If trouble persists, replace the R478B with a new one. C. IF PILOT DOES NOT LIGHT WHEN PILOTIGNITION LAMP LIGHTS, the trouble Is outside the R478B. 1. Check the pilot gas cock. 2. Check the pilot valve. 3. Check the Ignition transformer. D. IF FLAMZ-PROVEN LAMP DOES NOT UCBT WHEN PILOT IS LIGHTED: HOW TO TEST ELECTRONIC NETWORK, TUBES, AND DETECTOR If C701SA Is used In prove pilot, remove It from mounting and bold a lighted match in front of sensing cell 1. B rslay 3 then pulls in, the electronic net work te In working order. a. Clean the C791 LA viewing window. b. Clean the sighting tube, then check the flame through the tube. 11 flams Is not steadily ta view, change draft, fuel-air mixture, or sighting angle to obtain a good view. 2. tt relay does not pull in under the lighted match test: a. Change the R478B vacuum tubes. b. If terminal ? Is used, clean the contacts of relay 4 as described under subject CLEANING CON TACTS. c. If necessary. Install a new C7D1SA. <L V trouble persists, replace the R478B with a new one. E. IF FLAME-PROVEN LAMP LIGHTS HOT RE LAY GOES OUT ONSAFETY AFTER PILOT-IGNITION LIGHT GOES OUT, the trouble Is outside the R478B. 1. Check the main-fuel hand cock. 2. Check the main-fuel valve. 3. Check any possible Interlock. 4. Check main-burner flame by locking through photocell sighting tube, tt flame is floating or being blown past 11ns of photocell sight, It Is normal for R478B to shut- down the tarner. Problem may be corrected by on* or more of the fallowing: a. Changing photocell line of sight. (Recheck ability at photocell to detect pilot flams. Rerun Pilot Turndown Test.) - b. Improving fuel-air ratio of main flame. c. Changing temperature of heavy oil (If used). d. Improving draft e. Altering combustion chamber to keep main-flame front near burner. CLEANING CONTACTS Relay contacts should be cleaned onlywhen a care ful check made as described under subject TROUBLE SHOOTINQ Indicates the possibility of dtrty coniacts. Then Inspect and clean the indicated contacts by spraying the contact surfaces wlthTVcontact restorer from a plastic squeeae-bottle or an aerosol can. No rubbing of contacts ts necessary. The contacts must be left clean and smooth. If more convenient, tha chassis may be removed from the cabinet for cleaning and tnspecttng the contacts. If any contacts arc found burned to the extent that they cannot be smoothed by careful use of a contact burnishing strip, a new R478B after first In specting and testing the corresponding external cir cuits) for short circuits, and eliminating any iborta. found. Do not use n tUe or abrasive paper on the contacts. Replace relay cover and tighten the cover retaining screws. A? 000147 Tr? 2iitJs m3I 6015 i,a' /tP Syt*m FP-2 *tng Type 26RJ-MeM 6011 iAND;PROGRAMM*NG^| .=->foy; aulomoIicbunery;: /:je *% X H - B - H X A T MI Seennar Tjrp* 48PT1 Fotura 1 - 1 ------------------ Firey* System TP-2 provide* Ignition and flame /allure protection /or Industrial and commercial oil, jit, or combination ott/ga* burner*. In con junction with operating, limit, and Interlock device* It automatically program* each darting,operating, and shutdown period. Tb* FP-2 System consists of a Type 26RJ8 programming control and a Type 48PT1 acanner wbleb ue* the 'Flretron* cell to viauaJly aupervlae both oil and gas name*. The FP-2 Sy*tem monitor* both main and pilot flame* and doe* not permit tbe main foel valve to be eaerglaed usle*a pilot flame baa been established and proved. With an alternate connection for burner* having direct (park Ignition, tbe unsupervlaed trtal-for-lgnltlon period la precisely reetrlcted to a sa/e abort Interval. Sptclficellom Tbe 26RJ8 control programe tbe operation o: blower and/or tamer motor. Ignition system, fuel valve, and modulator system In a proper se quence which includes suitable purge period* before Ignition and after tamer shutdown. Addi tionally It 1* designed to de-energixe all fuel valve* within 1 to 4 second* upon loss of flame elgnal. Tbe oontrol recycle* automatically each time tbe operating or Umlt control closes, or after a power failure, tat locks out and must be reset manually following flame failure. Tbe FP-2 System Incorporate* a safety check ing circuit that le effective on every start. Any oondltloa which will cause tbe flame relay to bold In taring tbe checking period will atop tbe program before any Ignition circuits are energized and, 1f sustained, will result In safety lockout. Flreye System FP-2, consisting of Control Type 26RJ8, Model 6018, and Scanner Type 48PT1 SUPPLY VOLTAGE (selectable) at 60 cycle*, 1 ph*e: 120 volt* (Min. 102v, Max. 132v) 208 volts (Min. 177v, Max. 229v) 240 volts (Min. 204v, Max. 264v) VOLT-AMPERE RATINGS: 2SRJ8 consumption: SSva Max. simultaneous connected load: 1965va (See chart at right and teat oe pagea 3 and 4 for additional rating information.) MAXIMUM OPERATING TEMPERATURE: Scanner Type 48PT1................................... 12SF Control Type 26RJ8.................ambient, . 12&T SHIPPING WEIGHT: 22 lb*. TEMONAL KATOCS (WAX.) FOB TYPE 3tXJ$ MODEL (Oil TefmiaaJ He. Ua4 bda*i > |j0/jceyj40 *. *e -r. 4 l*aiti*a )M vi Ttuifimc^ a*4 m (tflnr 125 n Pair Ce*kUatiM 7 Mala ty n FUm Duct rxt VxJr(.) lmtw * m 20* 2*e Blraef Fall Uit J.l LJJ 2.1 Itow m Uctit but Kl 20.0 17.4 Banif Aluawc 270 Flirt Dry Aiwa J* n Flirt Daly 10*. u, 1) Maluw 12J * PltM Darr C*hUt4 Aiiartam 2 a Max. * )0* Max. 04.E.C. Oaxa 7> fm Ifaltla* m4 Feel Valve reflate m eteeUW vaJvee ee t**HeaUa mi a*]eve14 aa4 aataeJa*4 Velvet* fMtilt *e Iicmt. Inatallatien Installing the Typ 28RJ8 Control Loosen tnumb screws at front of chassis. Pull out chassis and place on ita back plate (Fix- 2). Select control mounting location on panel board or upright aurface that la free from excessive vibra tion. Secure boualng with acrewa or bolta ualng Figure 1 for drilling dimension*. Alter the boualng la wired, (Fig. 3), replace unuaed knockout pluga Plug chassis securely Into housing (Fig. 4), and tighten captive thumb acrewa. Control and Scsnnor Wiring " Make wiring connections at terminal panel at bottom of housing (Fig. 3). Separate knockouts are provided for conduit connection# for line volt age, and scanner circuits. Follow approved wiring diagrams. Connect bare wire directly to screw posts -- without lugs. Use suitable wire enclosed In rigid or flexible conduit for power connections. All wiring must comply with the National Electrical Code and local codes. Splices must be made only in troughs or Junction boxes. It is Important that cross-phasing be prevented on multiphase installations. The common of all control components (magnetic a tarter coil. Igni tion transformer, pilot and main fuel valves, etc.) powered by the Type 26RJS Control must be con nected to the common of the control -- Terminal 1 (20B-240 volts), or Terminal 2 (120 volts). The control bousing must be grounded either by the normal conduit ground or by an added ground ing wire. Before applying power, make aure AC Line Plug la is its proper socket. Attach the cable sup plied with the scanner to a Junction box (Fig. S). Splice the cable wires to a pair of wires not smaller than #18. Install the complete run In a separate conduit to the knockout directly under Terminal IS of the Type 26RJ8 Control housing. Connect black wire to Terminal 14; white wire to Terminal IS. Continuous conAilt bonding between scan Figure 5 ner and control la man datory! Scanner may be located up to 100 feet from control. Do not pats scanner wiring through any Junction box containing other wires. Do not run other wires through scanner conduit. This Is a Ul, requirement. Electrics! Rating Com!derations--------------------------- Electrical ratings of Fireye controls, regardlesa of the terms in which they are slated, are baaed on normal circuit current In amperes mul tiplied by nominal circuit voltage, called voltamperes and abbreviated as VA. Other electrical rating terms must be converted to VA wbea computing total connected load. If stated In amperes at a given voltage, multiply volts by amperes to get VA. If statedinborsepower, use the ampere figure specified in the National Elec trical Code for that single phase horsepower at the appropriate voltage and convert to VA. If the connected load la rated In watts, convert to ap proximate VA by dividing the rating In watts by an appropriate factor as follows: Magnetic coll (relay, solenoid valve, etc.) . .35 Motor.........................................................................75 Resistor (electric beater, lamp, etc.) .... 1.00 (Example: for solenoid valve rated 14 watts, di vide 14 by .35; approximate VA la 40.) The types of load permissible under the various rating terma which may be applied to Fireye con trols are as follows: Running and Locked Rotor Amperes la a rating intended specifically for motors, but a non-pilot duty load (see below) may be applied If normal and Inrush currents do not exceed running current rating. Alao an Indicator lamp may be combined with a motor load If the total of lamp Inrush (fig ured at 10 times normal current) and motor locked rotor currents does not exceed the locked rotor rating. Horacpower rating implies that running (or full load) and locked rotor amperes of a connected motor may Dot exceed those specified la the Na tional Electrical Code (at the nominal supply volt age) for a single phase motor of horsepower cor responding to that specified In the rating. The non-pilot duty load and Indicator lamp options ap ply aa above. VA Pilot Djty rating permits the connection of relays, solenoid valves, small motors, Indicator lamps, and other electrical devices under the con dition that normal operating VA may not exceed the rating. Inrush (or locked rotor) VA may not exceed ten times the rating. AS 00014 Electrical Rsling Canel Jtrsllsn* (csnt.)---------------- VA ratine not specified pilot duty permit* the connection of tr*nformer and *tmllar device* wherein the Inrush current Is not considered to exceed the norms) current. The term 'Inrush* ss applied her* relates or dinarily to a device wherein a part of the magnetic structure la free to assume two defined position* (such as a solenoid plunger) and signifies the cur rent which flows in the short Interval between energization of the coll and seating of the moveable structure In Its energised position. The term also relates to resistive devices which operate at In candescent temperatures (such as a lamp) where the cold resistance is much less than the hot realatance and where accordingly the current during the abort Interval between energization and in candescence Is considerably higher than normal operating current. There are no universal formula* for converting one type of rating to another. Thus the VA pilot duly portion of s combination rating can not be arbitrarily Increased )ust because the other por tion (a non-pilot duty VA ratlng.forlnatance) la not being used. There Is likewise no formula to con vert AC rating* of Isolated contact* to DC ratings. The use of contacts In DC circuit* Is not sanctioned Unless a DC rating Is ipeclfled. The maximum simultaneous running current load on the circuit supplying the Fireye control may not exceed 2000 VA. Since the control Itself is rated at up to 35 VA, the total load connected to the control (exclusive of flame failure alarm devices) may not exceed 1965 VA. The ratings tabulated on page 1 are the maximum permissible for each terminal. In models where the total of maximum permissible loads on all ter minals exceeds 1965 VA. it will be necessary to restrict the load on one or more terminals to stay within the 1965 VA limitation! Ratings ss they affect the contact* within the Fireye control are established on the assumption that no contact will be required to carry lnniah currents mors often than once la fifteen seconds. The use of limit, Interlock, or operating control switches that do not make positive contact at clo sure and which give rise to 'chattering* of relays within the Fireye control or of device* energised through It may lead to premature failure of switch ing member* In the control. Similarly, the con tacts can not be expected to handle short-circuit currents without possible damage. It Is therefore of vital Importance to make a'dry run* check of the control system (with manual fuel shut-off valve* closed) following the automatic opening oft control system fuse or circuit breaker, or following any known Instance of relay or switch chattering! Because of the special hazards that could accom pony welding of the contacts which control the fut valve circuit, those contact* are made of a high] weld-resletant material. Am a further precautloc the circuit to (ennlnal 7 1* protected by a 6 amper last-blow fuss. This fuse is accessible from th chassis front and is located between the test Jacks If this fuse should ever blow, do not attempt forth t burner operation until H has been ascertained this there is no contact Canute and until the contro has operated normally in a'dry run* check. Scanner Type 48PT1 -- -------------- Install the Type 49PT1 Scanner as recommeode by the burner manufacturer. If no Instructions ar provided, the scanner must be ipplled to fscllltai monitoring of the pilot and main flame*. The fol lowing description of operation of the FSretron ce will assist In making such an application. Operation of Flrstron Cell----------------------------------- The active element of the FJrelron cell Is a tear sulfide (PbS) semiconductor whose electrical re sistance instantaneoualy changes In accordance with the amount of Infrared and visible rsdlation I receives from sources within Us view. Such radi ation originating in a combustion chamber mi; consist of s steady radiation from hot refractor; or metal and 'an average valve of flame rtdlatlor which continuously fluctuate* In magnitude by ai amount and at a rate which are function! of the type of fuel and combustion condition*. When .a DC voltage is Impressed serose the cel and a aerie* resistor, the fluctuation of cell re aistance corresponding to fluctuation of flam radiation produces a fluctuating voltage across th cell. This voltage Is termed 'flame signal* and 1 fed to an amplifier. The amplifier responds to s fluctuating voltagi but not s steady one. It therefore responds to i fluctuating flame signal but not to a steady refrac tory signal. Further, it U 'tuned* for maximuc response at a frequency of 10 cycles per secon (t fluctuation rate found In all flame*) and has rel atively little response st power line (60 cycle) an very low (1 cycle) frequencies. When ampllfle flame signal exceeds a given magnitude, It cause energization pf a flame relay. Whereas the system doe* not 'detect* hot rt frsefory,excessive steady rsdlation reduces flic signal. The same effect -results from excetl< scanner temperature. To tvold nuisance shut downs, It ! Important to avoid sighting hot rt fractory and to keep scanner temperature lo (never over 125F). 77 000150 Appllcrlicn Pi*c*di/r Scanner Type 48PT1-------- The general instructions which /olio*, apply to lnstdlntlons of a single scanner which monitor* both pilot and ada dune*. If separate *c*nncr* are uatd for pilot and main flame*, consult the burner manufacturer for Installation Instruction*. 1. Locate scanner sight tube point of entry be* low and close to the burner Ignition assembly (Fig. 8) and drill a 7/8* bole through the boiler or fin* oace wdl. Tba sight tube, a 4 *8' length of 1/2* black Iron pipe, will be fixed to the bole when the proper position has been established. 5. Scanner must not dght on refractory which will become incandescent during burner operation. 6. Scanner must not be aUowed to exceed a temperstwe of 125F. For precise adjustment of the scanner viewing angle, Flrtyt Swivel Mount (Part No. 80-302) 1( available. If It is necessary to restrict the area the scanner views (to reduce sensitivity, or be cause of unsatisfactory background), use Flreye Orifice Set (Part No. 10-88), I 2. Position the scanner eight tube eo that scan I ner Use of sight will cross the Intersection of pilot flame axle and mdn flame (Fig. 9). Tack weld the debt tube to the point of entry bole. Should It i be necessary to remove refractory to obtdn the proper line of sight, prepare a straight bolt not less than 1-1/4* 1.0. Flare this bole slightly an It enters the combustion chamber. 3. Scanner must have unobstructed view of both pilot and main flames (Fig. 7). scaxxu Hurr kavi unoeiTnucTio vile or runic a o1 WI MTfwl luffMI 4. Both pilot and mdn flamea must completely cover scanner fleld of view (Fig. 8). vljimc must cca^urriLV COVIH 0MT OPOtlM* Wfae Keeping the Scanner Cool------------------ _____ The FIretron Scanner (Temperature Limit 12SF.) ahould never get too hot to grasp comfortably in the hand. Keep,the scanner cool by one or more of the following methods (Fig. 10). L One 6* to 8*jehgtb of pipe between scanner and bot furnace front plate. 2. Cse InsolaUng tube (Part No. 38-88) on the end of the iron pipe. 3. Force air Into sighting tube. 4. Make sure sighting tube does aot extend mors than halfway into refractory wdL 3. One Flreye Sealing Onion (Part No. 80-801) when using method 3 above. Relay, Leckeut Switch end Timer Operetian A. Master Relay (RL1) la located slightly above center of chassis. When all starting clrculta are closed and tube* are at operating tempera ture, the Flame Relay (RL2) closee an Initiating circuit to RLl which then pulla In. Only with RL1 energized la power made available to the Ignition and fuel valve twitching clrculta. RLl remalna energized from the atari of a program until a limit or operating control opene or the lockout awltch tripe. B. Dame Relay (RL2) la located at top right of chaaala. it Inltlatee a program by doling In responee to a checking algnal. After checking algnal la removed It reaumet Its open (de energized) poalllon until tuch time aa It la re energized In response to flame signal. It then remalna energized until flame la extinguished either by opening of an operating or limit con trol or as the result of unstable combustion conditions. C. The lockout awltch (LS) la located to the right of BL2 on the chassis. It trips (contacts trans fer to safety position) following flame failure Ignition failure, or failure of RL2 to assume Its de-energized position during the safety check period: It la a thermally actuated de vice which tripe after Ite heater la continu ously energized for about one minute. Its contacts will not automatically release from the safety position and must be manually reset after a cooling period of two or more minutes. D. The timer (K) la located at the lower rlghthand aide of the chassis. It consists of multipleleaf switches actuated by cams driven by a synchronous motor. The switches operate in i non-adjustable timed program to control (lx association with RLl and RL2) all externa: loads except alarm. The timer Itself la vari ously controlled by RLl, RL2,,and Its owr contacts. It may also be actuated manually (foj teat purposes) by a knob on the end of the earn shaft. Timer shaft position la Indicated by i drum type dial. Fljvt* W 79 *5 000152 OPERATING SEQUENCE: FP-2 SYSTEM WITH TYPE 2SRJ8 MODEL 6018 With proved pilot. Timor nm.imo {Second*) O DUI Indication 0 BURNER STARTUP Action Operlln< control ctoci. (If powr hie been off, there la no action until lubaa nrm op), name relay la enerttaed, followed bp muter rally, timer molar, and burner motor (Term, t). Modulator low fire circuit (Trm. 10-13) opena, high fire circuit (Term. 10-13) cloeet. 7 Checkins atxnnl off,' Dame relay abould de-eccrflxe within 4 aeconda. 20 Modulator hl^b fire circuit (Term. 10-13) open*, low fire circuit (Term. 1(5-12) closes. 25 X If for any reaeon flame relay doe* not drop out, timer atopa until lockout switch tripe. With operation normal there la no pause here. 45 i Ifnlllon oo (terminate 3 and (). SS 2 fuel valve on (terminal 7) (assuming pilot I* proved). 70 3 Terminal 5 IgnJUoo off. Modulator lev (Ire circuit (Term. 10-12) open*, automatic circuit (Term. 10-11) cloaca. IS 4 Terminal 5 Ignition off. ics DOT End of starting cycle; timer motor atop*. Burner operate* until heal demand te satisfied. BURNER SHUTDOWN JOS DOT Operiilrf control open*: master relay and fuel valve (Term. 7) de-energlsed; timer motor energised; modulator automaUe circuit (Term. 115-11) open*, lev fire circuit (Term. 10-12 cloaca. 120 0 Burner motor circuit (Term. 1) and timer motor de-entrylaed. Syaiem la ready for startup whenever operetta* control train cloaee. Direct apart Ipiltleo. (Terminals 1 nod 7 oo&aected lofether). Timer Rotation (Second*) Dial indication BURNER STARTUP Action 0 0 Operating control elect*. (U power ha* been off, there 1* no action until tubes warm up), name relay le energised, followed by maaur relay, timer, motor, and burner motor (Term. 1). Modulator low fire circuit (Term. 10-12) opens, hJgh fire circuit (Term. 10-15) cloee*. 7 Checkin* alptnl off, flame relay abould de-enerylaa within 4 second*. 20 Modulator hlyh fire circuit (Term. 10-13) opana, low fire circuit (Term. 10-13) cloata. 25 X If for any raaooa flame relay doe* not drop out, timer atopa until lockout awttch trip*. 45 1 tgnltloa (terminal 5) and fuel valve (terminal T) energised. 55 2 No action unices flame ha* not been established and/or detected, in which cant fuel valve and ignition art de-encrflied. * 70 5 Terminal 5 Ignition off. Modulator low fire circuit (Term. 10-12) opens, automatic circuit (Term. 10-11) clooee. 10S DOT Tad of starting cycle; timer motor stop*. Burner operate* until heat demand le eatiafied. BURNER SHUTDOWN ICS DOT CpenUnf control opena: me.ter relay and fuel Hire (Term. T) de-enerfLaed: timer motor enerslaed: modulator aulomeile circuit (Term. 19-11) open*, krw fire circuit (Term. 19-13) cloaee. 129 0 Burner motor circuit (Term, t) and timer motor de-eeeryleed. Bysum Is ready for startup whenever operating ettfu/o^jal^loees. ' 80 4X 000153 Schematic Circuit FIfura IS PUL roiTiQ* Tret !* F REYE PROGRAMMING CONTROL 0 3) W00CI. |OI> I U.S. AATEMT HO ---- l.Ril.VM ALSO fOftClON Nt(kT| 1SSUC0 AMO PCM04MA OOaifiOM GDEC1I0mS ~orr(TRANSFORMER - $00 A,VALVE-'ISWA'iOTOtfTV) VR|aV-FOA<AM AEAtQQ II set - lvHvitt SO Itt - ItfStMuHl 10 SEC -- UMftvACRV'StO ICAMtMALl A AMO T| AllOT o* |At> 10 VQLtilC COMTMOC SOlTCtttS FUEL VALVE 050 VA AitOT OyTTl alarm ISO VA AtlQT OifTTl MO0VLATO* SVITCNIM* CONNECT*** Itn VARH.0T QUIT) "mwsrrwimjw- M a* U a, AUMMIM0 ?VI1T*4 J.* lockco aotoa JJljotSTrr PlfMTM U 81 ^"000154 InttcWctlon Tasting----------------------------------- -- Test Accasicrls* Tbi following teal equipment Is recommended for checking out new installation* end routine troubleshooting: 1. DC Voltmeter (1000 ohm a per volt or creator). Rang*: 0-1 JO volta (rtf. IT). Any food multimeter la suitable and can ba uacd to measure AC and DC roliagaa, eh sc* for continuity, abort clrculta, and fTOunda. The DC volt* mater laada plug Into teat jacks on the oontro) cbaaala. For Mtlafaclory operation, the malar will read aero volta artlb no flame preeent and aleady 60 to 100 volta when tie scanner 'aeea* a flame. AC line and load vollagea may be checked at the expoed terminal* at tit bottom of tba cbaaala 2. Three-prong Teet Plug (Tig. 18. Part So. 10-80) roplacea tie AC Lina Plug In tic 26RJS Control Cbaaala, electrically die connect* lie timer motor, permitting manual control of tie firing cycle. 3. Flame Signal Attenuator. Directly above tie vacuum tubea on tie chaaala la a receaaed pin, which when grounded to tie chaaala by a clip cord (Fig. 19), will re duce the aenalUvtty of lit flame algnal amplifier 40% for (eat purpose*. For Burner with Pilot Ignition -- ...... ' Checking Sconnar Viewing of Pilot Flomo - 1. Make aure that control and teanner have bean prop erly Installed and wired In accordance with the preced ing Instruction*. 2. With power OFF, replace AC Lin* Plug with ThreeProng Teat Plug. 3. (Optional) Ground the attenuator pin to tie chaatla. 4. Plug DC Voltmeter leads Into teat jack* oo control chasila (Red-plus: Black-mlnue). i. Route timer knob until *0* appears on timer dial. 6. Turn power ON. Walt until the tubea warm up and both relays are energized. 7. Route timer to dial poeltton*X*. Walt until the flam* relay (RL2) la de-energlxed. I. RoU timer to dial position *1*. Make rur* Ignition la eneigiaed. If pilot does not Ignite within IS seconds, turn ---inner *witch off and repeat from step S except al low is to 20 aecoods purge lima between steps T gad I. Repeat aa necessary until pilot flam* Is established. 9. Observe reading oa voltmeter. Reading should be teady, between 60 and 100 volta, de. If tie reading fluc tuates, It will be neceasary to adjust the pilot flame and/or scanner viewing angle. Continue adjustment until steady, correct reading la obtained. NOTE If pilot flam* la not detected within about 60 seconds, control will leek out, making It Inoperative. II wtU be neeaaeary to allow two or thra*.minutes for tb* ther mal element to cool and to raaat tb* control manually. Then repeat from step 6. Checking Scanner Viewing #f Main Flam# -------- -10. Turn power OFF. Replace 3 prong teat plug with 4 prong AC line plug. II. Reset timer to *0* and turn power ON. 82 12. Aa dial rsacbta position *2*,watch far tsubllahmeat of main flam*. If flama la not eaubllihed wUMn if seconds, turn burnar switch OFF, then return to ON allow control to recycle normally for a new lighting trlaf. (Note; tto an Initial starting attempt', pontons of 'fuel lint* may be amply and require 'bleeding* time. It Is better to accomplish this with repeated short Ugbtlng-trlal periods with Inlarvtnlng purge periods than to risk pro longed fuel Introduction nt n time when burner adjust- mente have not been completed and the minimum pilot teat baa not been conducted. Do not rtpaat unsuccessful lightly attempts without rechecklng burner and pilot ad-' (uitmrale(flighting does not occur within S second* nftsr fuel Introduction Is vtrlfled or can bt reasonably as sumed.) 13. Wbsa main flame 1* established, leave burner on nnd let timer progress until ignition shuts otf (either dial po sition *3* or *4* ns tie esse may be). II scanner main flam* sighting 1* reasonably good, th* flam* relay will stay energised, main flams will stay Jit, tnd the timer will progress to dial *dol* position and stop. If flam* goea out due to Instability without Ignition, readjust burner and repeat from step 11. If flamais stable but flame relay drop* out because of poor sighting, realign scanner sight tub* and repeat from step 2. 14. With step 13 completed and burnar ramalab^ Utwith tlmar at 'dot* position, readjust burnar aa necessary for correct flam* six* and optimum combustion, then racbeck for proper lighting. If scanner t properly sighted, th* DC voltmeter will now register a aleady go volts or more with pilot flam* only and with main flam* only. Repeat scanner and burner adjustments as necessary to obtain this condition tf It does not exist Initially. 15. With all steps through 14 aatlifaclortly completed, remove attenuator connection (If used) and proceed with minimum pilot teat. Minimum Pilot Teat----- -- - . This teat assures that th* scanner will not detect flam* too small to light otf th* mala flam*. B must bo mad* (a) oa *vary new Installation, and (b) following any change of scanner location or viewing angle. Do not conduct this teat with (he attenuator pin rroundodl 16. Repeat step* 2, 8, f and 7, than advance timer to dial position *1* so that pilot tgnltao. 17. Reduce the sU* of the pilot until tho flams relay la observed to drop out, than slowly tncraaa* th* size of pilot flam* Just to th* point whar* th* Cams relay pull* In. This la called minimum pilot (Note Fig*. 20, 21, 22) 18. Advance tlmar to dial position *2* to energise mala fuel valve. CAUTION: If mata flam* dooo aoi Igalt* tn approximately th* aim* Una as II did with normal tell pilot flam*. Immediately nun to* burnor switch OFT I Raaltga th* tcaaMr sighting tub* no that detection re quires a larger pilot flam* and repeat minimum pilot uot Repeat this process until main flam* lights reliably on ttvenl trials. It. After minimum pilot teat la completed, Increas* pilot flam* to normal alio. Slacking DalocTtan with Hat Combustion Sambee With all th* shove outlined tests and final burner adluatmeste computed, operate tb* burner (observing manufac turers warm-up Instruction*) until combustion chamber Is at maximum axpoctad temperature. Recheck for adequate signal with main flam* only and with pilot only. If steady output voltage of 60 or more volte DC la not measured ai the teat Jacks, ronllga scanner sighting to obtain suitable output voltage and than repeal all steps through 19. For Burnor with Spark Ignition (Ho Pilot) --------------Sacking Scanner Viewing of Main Flomo 1. Proceed according to step* 1, 3, 4 and 8 as outlined above. 2. Turn power ON. After bib** warm up, relay* will pull la and timer will start. / 1. Ai timer reicbea die) poltlool,w*tcb for main flune to be esubltahfld. If flame If Dot eatabllabed by tie Urn* dlil poalllon *2' I* reached, turn burner (witch OTT and lien OK again and illow control to recycle normally. CAUTION: If fuel ! obeerved to cater combuitlon chamber nnd Ignition doci not occur >1 onco, but burner ewllcb OFF end check electrode eeltlnga. So not repeel Ignition attempt* unleia n good (park can be obatrved In a poeltlon where tie fuel will be readily lentted. <. If acanner lighting la correct, DC voltmeter will regia ter Heady *0 volt* or more. If It doe* not, abut burner OFT, realign acanner, and repeat lit check. If voltmeter reflatera aaUefactorily until Ignition abut* off at dial poaltlon 3, and then reading become* unatcady, readjuat burner to obtain atablc flame both with and with* out Ignition on. S. Remove attenuator connection Of uaed). Checking Pilot Flomt Failure Protection .. 1. Shut off the fuel to tie pilot burner. 2. Start tie control cycle. 3. After (3 eeconde* purge period, lie plldt aaaemblv will be energixed. ' 4. Becauee no pilot Same 1* detected, the pilot aeeembly win abut off after 10 eeconde. The main fuel valve will not ba energlaod. 5. The programming timer will complete IU cycle dur ing which Una the lockout ewltch wtu trip, effecting a aafety lockout and actuating the alarm (If uaed). Checking Main Flam* Failure Protection___________ 1. Start the burner la the normal manner. 2. After tba atartup programming ban been completed, abut off the main fuel eupply. 3. Immediately alter the flame fella, the main fuelvajvt will etoee and after approximately SO aeconda, the lock out (witch will trip, actuating the alarm. t. Following a IS aecond post purge or rpia-dowa period, the blower motor will atop. S. Tba lockout (Witch may be reaet after allowing the thermal element to cool (approximately 2 minute*). ncrnACTonv ^ Vvw\.-.v>nv, kh a ,/\ IV' V [f) 1 MAIM FLAMK | Ilwwww^ PILOT ft^ ICAMMtft Bur*** tk*tck Oftlmwoi ptl*t ftnw, ntur 21 83 #-S 000151 . Servicing Trouble* In FP-2 System installation* can be readily isolated by following the approved procedure In the a*, quene* (Wen below. Before beginning any troubleshoot ing, however, make *ura that: Inalitlatloo and wiring baa been made la aceordanee with Ina traction! la Ible bulletin. 2, Chaaala la amraly plugged la and thumbscrews tightened; AC line plu* U la proper aocket; lockout awllch la react. la the following ubulatloa, troublea appear within boaea. and poaalble cauaea are lleted below the boxes. CONDITION: Zero voltaic at Termlnale 1 and 4 (201241) volt lnetaJIclioa) or at Terminal* 2 and 4 (120 volt tnaLUtatloa).____________________ 1. Die connect Switch afl. 2. Blows fine. 3. Broken wire. 4. incorrect wirln|. j1 CONDITION: Ineufilcleot volti|e al Termlnale 1 and 4 or 2 and 4. 1. Minimum operating voltage la 177 volts for 201 volt connection; 204 volte tor 240 volt connection; 102 volte for 120 volt connection. CONDITION: Zero voltage at Termlnale I and 3 (204240 volt Installation) or at Terminal! 2 and 3 (120 voll installation). 1. Open limit awllch circuit (Preaaura, LWCO ale.). 2. Broken wire. 3. Motorized stack damper control is cloied position. 4. Incorrect wiring. CONDITION: Flame relay RL2 does not pull in at startup. | 1. Vacuum tubca not warmed up. 3. Defectlr* vacuum tuba. 3. Timer dial not al *0* position. 4. Lockout awltcb la tripped. 1. W to B circuit open (operating controls and starting aterlodu.) 4. Poor connection al plug-la Jacks. Check to make aura they are not spread open. 7. Relay armature blocked open. 1. Contacts L3-1, JC1-J, K3-2, or K3-3 open or dirty, t. Defective programming control; replace. CONDITION: Matter relay (RL1) dost not pull In. 1. Flama relay doee not pull la. See check llat above. 2. RL2-2 coolerla open or dirty. 3. RL1 armature may be mechanically ituek open. 4. Defective programming control: repine#. CONDITION: Maeter relay pull* la but timer docs not start. 1. Contacts RL1-1 or K4-1 are dirty or open. 2. Ttmar motor la mechanically bound; check by ro tating timer knob. 3. Defective programming control; replace. CONDmON: Programming timer starts. Blower motor dots not alert. 1. Insufficient voltage between Terminals 1 and 1 (204240 volt operation) or 2 and g (120 volt operation). 2. Blown motor fuse. 3. Motor starter overloads tripped. 4. Burner motor Incorrectly wired. 3. Defective motor or alerter. CONDITION: Modulator motor does oot drive toward p-dimp*r poattlra. 1. Modulator motor not powered. 3. Llukaft lammed. 3. Incorrect wtrlaf. 4. Contact* RL1-S. K7-2, K3-1 dirty or open. 0. Contact! RL2-4 do oot open. 1. Defective modulator equipment. S4 CONDITION: Flama relay HU dose not drop out before 'X* appear* on Umar dial. 1. Ineorrect scanner wiring. 2. Scanner a tee flams caused by leaky fuel valvae, burning carbon, or loot.or as adjaeast burner la multi ple burner installations. 3. Flama relay la mechanically bald Is. 4. Defective vacuum tuba. 3. Contacts K3-2 or K3-3 do aol epm. 1. Defective control or acacmtr. CONDmON: Master relay drop* out after timer starts. | 1. Contact* RL1-3. X3-1 dirty or open. 2. Air flow awltcb is not dosed (W to R). 3. Lockout awltcb banter ia open. CONDITION; Modulator motor doe* not drive towird closed-dampar position at about 20 seconds. 1. Modulator motor not powered. 2. Linkage Jammed. 3. Incorrect or faulty wiring. 4. Contacts RL1-3. K7-2, K3-2 dirty or open. 5. Defective modulator equipment. CONDmON: Timer dial reaches position *1*. Pilot fl&ai U Bot eaUbUbd. 1. Insufficient voltage between Terminals 1 and 3, 3 (203-240 volt operation) or 2 and 3,4 (120 volt operation). 2. Contacts RL1-4, Kl-2, K2-1 or K7-3 dirty or open. 3. Defective gaa valve. 4. Defective'Ignition transformer or electrode. 5. Improper electrode setting. (. Plugged pilot burner. T. Insufficient gas pressure. 8. Improper pilot burner adjustmat. . Ignition assembly Incorrectly wired. CONDITION: Flam* rtlay (RL2) doee not pull In when pilot flame lights. 1. Pilot Dame tee small. Make sure gaa pressure la not lees (ban that specified for the pilot burner. 2. Scanner eight tube obstructed, or scanner less dirty. 3. Scanner sighting 1* Incorrect. 4. Scanner Is Incorrectly wired-- correct wiring la white wire to Terminal 13; black ertr# to Terminal 14. 5. Scanner la too hoc I. Scanner view* hot refractory. .T. Flame relay la mechanically bound. 3 Defective tube or cell, or tubes reversed. >. Contacts Kl-3, dirty or open. 10. Defective scanner. II. Defective control. CONDITION: Timer dial reaches position *2*. Mala fuel vahre stays shot' 1. baufSelant voltage b*tween Terminals 1 and 7 (204240 volt operation) or 3 and 7 (120 volt operation). 2. Contacts RL2-J, RL2-4 or Kl-1 dirty or open. 3. Defective valve. 4. tooorrect wiring. .3. Pilot flam* not detected. 3 Blown fuel valve circuit fuse CONDITION: Puel valve la energized. Main flame does not light off. 1. Inadequate pilot. 2. 'Incorrect burner adjustment. 3. No main futl. CONDITION: Main flam* lights end then goes out. | 1. Lockout switch has tripped. Allow to cool for two minute* and reset. /pS000157 Servicing 2. limit, operating ooctrol circuit, or air flow (witch open. 3. CoaUcU RL2-2.X3-1 dirty or open. 4. Scanner U "blinded' by too bright rofloctioa of flame oo inside surface of sighting tube, or by sighting incan descent rtfnetory. If scanner tj corroctly installed, restrict view with orlflco la sighting tube. CONDITION: Timer dial reaches position *3* or *4*. _____________Pilot flame dote aol go out._______________ 1. Csj pilot reive is stuck open. 2. Contacts K7-3 or K2-1 axe stuck cloesd. 3. Control circuit wiring la inooittel or cross-phased. CONDmON: Timer dial reaches positiea *3*. Bo*i- iator motor dots not respond to modulation controller. 1. Modulator motor sot powered. 2. Setting of modulation controller incorrect. 3. Linkage Jammed. 4. Incorrect wiring. 5. Contacts 1(7-1, RL1-S dirty or open. 6. Defective modulator equipment._____________ | CONDITION: Main flame goes ut when pilot shuts off~ 1. Scanner does not *eee* main flame. 2. Incorrect burner adjustment. 3. Incorrect wlrirg to solenoid fuel valve. Flretron Cell: Estimated life 20,000 hours, when oper ated within ambient temperature limits. Tbs scanner lens should be cleaned as often as operating conditions demind. Tubes: Types 12AX7; UBH7A; have an eatimitod lift of 10,000 hours. Annual replacement recommended. Re placement tubes are available from local radio tube upply source*. Fuel Valve Fuse: ( ampere, 250volt. Type 3AG fast blow. Do not substitute (except for smaller ampere rating If desired) and do not renew without observing procedure described os. [ CONDITION: Timer does not slop el 'dot'. 1. Contacte X4-i or RL1-2 stuck closed. CONDITION: Timer does aot rotate to *0* whea oper sting or ilmlt control opens. 1. Contacts XU-2 or X3-1 dirty or open. 2. Limit switches Incorrectly wired. CONDITION: Xhiring post purge period modulstor moioi does not drive toward damper-closed po sition. 1. Modulator motor not powered. 2. Linkage Jammed. 3. Incorrect wiring. 4. Contacts RU-6 dirty or open. 3. Defective modulator equipment. CONDITION: Timer does not atop at *0*. 1. Contacts RL1-1 or K3-1 stuck closed. 2. Control circuit wiring crose-pbiatd. 3. Limit or operating switch circuit closed. CONDITION: Burner molor does not slop when time: dial retches *0*. 1. Contacts RL1-1 or^lU-l stuck closed. 2. Control circuit wiring cross-phased. 3. Limit or operating switch circuit closed. 4. Molor starter is mechanically stuck. 5. Motor starter it incorrectly wired. Contacts: All relay contacts are designed with tdequa! wiping action for self cleaning under normal condition/ la atmospheres carrying excessive dust or oily vapori contacts may require occaalonal cleaning. Use only fins grads of crocus doth for cleaning. Do not fils. Humidity Effects: To protect against high rsolstanc leakage Is the electronic circuit resulting from hig humidity, It is recommended that the 28RJ8 Control b left powered oontlnually even when not Is operation. 1 It la necessary to abut down oomplstslj for anextendo period, power should bo turned oo for 48 hours before putting tbs control back la operation. We guarantee to replace or, ai our option, repair any products or parts thereof (except fusts, electrode tubes 'and cells) which are found defective in material or work manship within one year from data of shipment. Oix ob ligation with roepoct to such products or parts shall bo limited to replacement or repair f.o.b. Cambridge. Baas, and la no event.shall we bo liable for consequential e: special damages, or for transportation. Installation, ad justment,, or other expenses which may arias ta occnactioc with such products or parts. Combustion Control Division ELECTRONICS CORPORATION OF AMERICA One Memorial Drive, Cambridge 42, Massachusetts IN CANADA: Electronics Corporation of Americo (Canodo) Ltd. 104 Advmvco Rood, Toronto 18, Ontario 85 jjg 000158 11 F4M74 LrM4 *50373 Bulletin CP-J Scanner Type 48PT1 FEATURES _______________________________________________ Frxrrz System FP-2 provide* ignition end flame failure protection for industrial and commercial oil, gas, or combination oil/ga* burners. In conjunction with oper ating, limit, and interlock devices, it automatically program* each starting, operating, and shutdown period.' The FP-2 System consist* of a Type 26RJ8 program ming control and a Type 48PT1 scanner which uses the "Founow" cell to supervise visually both oil and gas flame*. The FP-2 System monitors both main and pilot flames and doe* not permit the mam fuel valve to be energized unless pilot flame has been established and proved. With an alternate connection for burners having direct spark ignition, the unsupervised trial-forifnition period is precisely re*tricted_^to a safe short interval. Model 6070 Is specifically designed to comply with FIA Requirements for auto matic gas or oil firod burners. C.SA. Fils tr 7989 The 26RJ8 control programs the operation of blower and/or burner motor, ignition system, fuel valve, end modulator system in a proper sequence which includes suitable purge periods before ignition and after burner shutdown. Additionally, it is designed to de-energize all fuel valve* within 1 to 4 second* upon loas of flame signal. The control recycles automatically each time the operating or limit control closes, or after a power failure, but locks out and must be reset manually fol lowing Aarae failure, or opening of the running inter lock circuit during a firing period. The FP-2 System incorporates a safety checking circuit that is effective on every start. Any condition which will cause the flame relay to hold in during the checking period will stop the program before any igni tion circuit* are energized and, if sustained, wii! result in safety lockout. SPECIFICATIONS Fiarrz System FP-2, consisting of Control Type 26RJ8, Model 6070, and Scanner Type 48PT1 SUPPLY VOLTAGE: 120 volts (Min. 102v, Max. 132v) at 60 Hz, 1 phase VOLT-AMPERE RATINGS: 2SRJ8 consumption: 35va Max. simultaneous connected load: 1965v* (See chart at right and text on pages 3 and 4 for additional rating information.) MAXIMUM OPERATING TEMPERATURE: Scanner Type 48PTI........................... ............. 125* F Control Type 26RJ8 ........ ................ ambient, 125*F SHIPPING WEIGHT: 22 lbs. TERMINAL RATINGS IMAXJ TOR TYM 1IRA MOO 11 1070 A___________________________________ Tifwwil in** L*H l|iw| A4 COfrtKt Antrim fcatinf at I20***0r Wtfi RaiH al )|`C < NfAtf f|f ClRfitvIO' 5 or A if ClIMtMIO* IfAlt AA Tflfit/otlMf Cm Pitot Vin S00*i iTimiAwmii !25*8*Pito< Oviy r )00i rTumftetooy) i)i h*< Dvty 500*8 iTraAW'ermtn 50*8 Pitot Owijr OF >00*1 iTr*n*/onrr 125<a Mai 0*tf 7 A * 10. M. a i) Mala Kool 120*8 Hotfii* i:o* l.il V|M l)0i PUat Ovty w 45*8 Pitol Dwtr *40*a Oftiiifii MxiniH l20*M#Klff V||( 250*a PUot Omit or 45*8 P>to< Over 1250*8 500*8 Motors** Vifwt luiwt Maim ttorv Mi*f Moiif Sunn 5.1 lAfl f Mil Ini >4.1 AlltpA - 1*4 AH AotO* m 250*8 Mol Omit AUrm XeOvltior 50* Pbt D*r 125*8 Pitot Oviy * i0*ou or 2 amp* JO *rmh A(* ailmwri iN . C Clave J> Stftevl ALL Ttmifiil lnifi|t IremONh Colvmia. A I. Total tOAAOVlH IM Ml WtSktH 2000**, 000159 MOUNTING AND OUTLINE DIMENSIONS SURFACE MOUNTEO ENCLOSURE S--H--f } /rlJ*MXU ^ " 44 - - - - - - - - - - j------------ *7 i 1 i! J1 Li ? *! 01 i t1r ;------------------ -4 b S8S89'39Sde 5: 5t---6-S--8- 888888 Q <" l ' ! 1 | 11 FRAME FOR CABINET MOUNTING f J! 1---- <ePTt-9000 A8PT1-IOOO CI*CVnT CONOtTIQ*>t IL*TIB to 1ICPW0I 01 T|M| QTaTIOW ... u.K.IIUII l.ncan M tm.l MIIWMHIIIH'* TYRE 2BRJS mn . IQI lM W Wl " HID--I FIREVE PROGRAMMING CONTROL 00 0 @ MOO CL *070 | MMl l)lMt HJIM *1 mo #*nn MWfiCTtflfl It CtCCTHOmCI eOl^OAATlOM OF AMCfltCA coturio* cenTiov. <>sio IIA <m-- Figuf* 1 000160 Installing ths Type 36RJI Contrsl Loosen thumb screw* at front of chassis. Pull out chassis and place on its back plate (Fig. 2). Select control mounting location on panel board or upright surface that is free from excessive vibration. Secure housing with screws or bolts using Figure 1 for drilling dimensions. After the housing is wired (Fig. 3), replsce unused knockout plup. Plug chassis securely into housing (Fig. 4). and tighten captive thumb screws. Control and Stonner Wiring Mske wiring connections at terminal panel at bottom of housing (Fif. 3). Separate knockouts are provided for conduit connections for line voltage, and scanner circuits. Follow approved wiring diagrams. Connect bare wire directly to screw posts -- without tup. Use suitable wir< enclosed in rigid or flexible conduit for power connections. All wiring must comply with the National Electrical Code and local codes. Splices must be made only in troughs or junction boxes. The control housing must be grounded either by the normal conduit ground or by an added grounding wire. Attach the cable supplied with the scanner to a junction box. Splice the cable wires to a pair of wires not smaller than 18. Install the complete run in a separate conduit to the knockout directly under Ter minal IS of the Type 26RJ8 Control housing. Connect black wire to Terminal 14; white wire to Terminal IS. Continuous conduit bonding between scanner and con duit bonding between scanner and control is manda tory! Scanner may be located up to 100 feet from control. Do not pass scanner wiring through any junction bos containing other wires. Do not run other wires through scanner conduit. This is a UL require ment. Elsclricol gatings: "VA" ratinp (not specified as pilot duty) permit the connection of transformers and similar devices whose inrush current is approximately the same as their running current whose total inrush current does not exceed 10 time: the rating. "Running and locked rotor" ratings are intended for motors. VA and VA l pilot duty) loads may be added to a motor load provided the total load does not exceed the published rating. To convert from watts to volt-amperes or horsepower, etc., refer to the National Electric Code Handbook. All published ratinp apply to AC loads. For DC ratinp, consult the factory. Published load ratinp assume that no contact be required to handle inrush current more often than once in 15 seconds. The use of control switches, solenoids, relays, etc. which chatter will lead to premature failure of switches in the Pireye control. Similarly, the con tacts cannot be expected to handle short circuit cur rents without damage. It is important to run through a test operation fwith fuel shut off) following the trip ping of a circuit breaker, r*blown fuse or any known instance of chattering. Because of special hazards that could accompany fusing of the fuel valve circuit contacts, they are con structed of weld resistant material. Operation of FIRETRON Cell The active element of the Ftxrraorf cell is e lead sulfide (PbS) semiconductor whose electrical resistance instantaneously changes in accordance with the amount of infrared and visible radiation it receives from sources within its view. Such radiation originating in a combustion chamber may consist of a steady radiation from hot refractory or metal and an average value of' Aame radiation which continuously fluctuates in magni tude by an amount and at a rate which are functions of the type of fuel and combustion conditions. When a DC voltage is irppressed across the cell and a series resistor, the fluctuation of cell resistance corre sponding to fluctuation of flame radiation produces a fluctuating voltage acrora the cell. This voltage is termed "flame signal" and is fed to an amplifier. "VA pilot duty" ratinp permit the connection of relays, solenoid valves, lamps, etc. whose total operat ing load does not exceed the published rating and The amplifier responds to a fluctuating voltage but not a steady one. It therefore responds to a fluctuating flame :;gnal but not to a steady refractory signal. Tur- 5000161 4 INilAUAiiUN ther. it ii "tuned" for maximum re*ponse *t * frequency of 10 cycle* per second (a fluctuation rate found in all flame*) and ha* relatively little response at power line (60 cycle*) and very low (1 cycle) frequencies. When amplified flame signal exceed* a given inaptitude, it cause* energization of a flame relay. Where** the system doe* not "detect" hot refractory, excessive steady radiation reduces flame signal. The same effect results from excessive scanner temperature. Tc ;void nuisance shutdowns, it is important to avoid sighting hot refractory and to keep scanner temperature low (never over 125*F). 4. Both pilot and main flames must completely cover scanner field of view (Fig. 7). Fl*C MUS? COMPiCTeiY COvta Sight onmK Applitolion Prsodur* -- Sconnar Type 4BPT1 The general instructions which follow, apply to in stallations of a single scanner which monitors both pilot and main flames. If separate scanners are used for pilot and main flames, consult the burner manufacturer for installation instructions. 1. Locate scanner sight tube point of entry below and cloae to the burner ignition assembly (Fig. 5) and drill a V,- hole through the boiler or furnace wall. The sight tube, a 4'-3* length of :A` black iron pipe, will be fixed to the bole when the proper position has been established. T.KII acraac'o mF *mt Figure 7 5. Scanner must not sight on refractory which will become incandescent during burner operation. 6. Scanner must not be allowed to exceed a tempera ture of 125'F. * For precise adjustment of the scanner viewing angle, Fntrrx Swivel Mount (Fart No. 60-302) is available. If it is necessary to restrict the erea the scanner views (to reduce sensitivity, or because of unsatisfactory background), use Fireye Orifice Set (Part No. 10-88). Kaaping lha Scanner Cool The Firetron Scanner (Temperature Limit 125*F.) should never get too hot to grasp comfortably in the hand. Keep the scanner cool by one or more of the following methods (Fig. 8). JgMMf pii mmt ftefXf mm rmtiwuvmrf Figure 5 Z Position the scanner sight tube so that scanner line of sight will cross the intersection of pilot flame avi and main flams (Fig. 14). Tack weld the sight tubs to the point of entry hole. Should it be necessary to remove refractory to obtain the proper tins of tight, prepare a straight hole not less than IV*' I-D. Flare this bole slightly as it enters the combustion chamber. 3. Scanner must have unobstructed view of bolh pilot and main flames (Fig. 6). Figure I 1. Use 6" to V* length of pipe between scanner and hot furnace ' ont plate. Z Use insulating tube (Part No. 35-69) on the end of the iron pipe. 3. Force air into sighting tube. 4. Make sure sighting tube does not extend more than halfway into refractory wall. 5. Use Ftarrz Sealing Union (Part No. 60-801) when using method 3 above. 000162 AUTOMATIC CA5 OR CK OURNCR - CAS ELECT** *lOT WITH $U*MC* MODULATION > *U ?>tst n* mi niU( 44<*Ii -m h hlil*t P >4Mt H 2*C*"*'Jt M"OWDWElWL S,wOT'Ov AUTOMATIC CAS/O*. C0M61NATI0M SURHCVI *CAS CLECTRlC^n.OT-wrTHe^NCR MOOULATON ZtftJS MOOCL SOTO 4-j 000163 6 RELAY, LOCKOUT SWITCH AND TIMER OPERATION A. Master Relay (RL1) is located slightly above center of chassis. When all starting circuits are dosed RL1 pulls in. Only with RLl energized is power made available to the ignition and fuel valve switching circuits. RLl remains energized from the start of a program until a limit or operating con* trol opens or the lockout switch tripe. B. Flame Relay (RL2) is located at top right of chassis. It is energized in response to flame signal. As long as there is a call for heat it remains energized unless there is loss of flame signal or unless the running airflow switch or a limit control opens. C- The lockout switch (LS) is located to the right of RL2 on the chassis. It tripe (contacts transfer 10 ** po*1Hon> if RL2 assumes and bolds its energized Position prior to "ignition on" or if RL2 assumes its de-energized position due to ignition failure, flame failure, or opening of the running air flow switch after main flame is established. It is a thermally actuated device which trips after its heater Is continuously energized for about one minute. Its contacts will not automatically release from the safety position and must be manually reset after a cooling period of two or more minutes. D. The timer (K) is located at the lower right hand side of the chassis. It consists of multiple-leaf switches actuated by cams driven by a synchro nous motor. The switches operate in a non-adjustable timed program to control (in association with RLl, and RL2) all external loads except alarm. The timer itself is variously controlled by RLl and RL2 and its- own contacts. Timer shaft position is indicated by a drum-type dial. ^_5 00016 4 TIMING SEQUENCE: FP-2 SYSTEM WITH TYPE 26RJ8 MODEL 6070 Cai o> oil prortn pilot. (No connection between terminals t and 7) Itlm'on Dial For unprorcn pilot or direct spark ijnition (Terminals 6 and 7 jumpered) differences in operation are marked with asterisk (). BURNER STARTUP (Seconds) 0 10 Indications Action 0 Operating control doses. Muter relay, timer motor and burner motor (terminal 1); also Dame relay on Code 32 & 3S units become cnerpzed. Modulator control switches |o to high firs position (10-11 opens, 10-13 dotes). ** Kunmni interlock (3-R) circuit must be closed at this point and throughout remainder of heating cycle. Interruption prior to Dial 2 results in control recycle. Interruption after Dial 2 results in safety lockout. Checkin! sijnij X3-3 opens, flame relay de-enerfsaes. Should flame relay remain enenned. RL2-3 opens, timer stops at 33 seconds, safety lockout will occur. 70 - ftuge ur flow interlock (terminal t to W cloud) must be satisfied for cycle to continue. 41 - Modulator control switches |o to low fire position (1013 opens, 10-12 doses). S3 X If. for any season, flame relay holds in. cycle timer motor stops until lockout switch tripe If starting ignition-interlock (W to 1 cloud) is not utiafied, timer motor stops until interlock is satisfied. 163 Ignjiiod (terminals J and 6) o. Terminals J.4 and 7 (Fuel valve) energized. 70 No actron unless (Umc Ku not beta csublahcd and/or detected, in which ease fuel valve and ignition are detnergmd. 273 Fuel valve (terminal 7) on {provided pilot is proven). 90 3 Terminal 3 ignition off. Modulator control switches to to demand poaision. (10-12 open, 10-11 cloud). 103 DOT Terminal 6 Ignition off. End of initiating cycle; timer motor stops. Burner operates uatd heat demand (Index) is uiisAcd. TerminaJ 4 remains energjad. BURNER SHUTDOWN 103 DOT Operating control opens: mister relay and fuel raise (terminal 7) detnergned: timer motor (Index) becomes energued. Modulator control switches to to low fin position (10-11 open. 10-12 doud). 0 I120 Burner motor (terminal t) circuit and cycle toner motor deenergued. System is ready for startup whenever operating control doses scam. 000165 I INSTALLATION TESTING Test Accsis.oriai. The followinf tt equipment is recommended for checking out new installations and routine troubleshooting: 1. DC Volbneter (1000 ohms per volt or greater). Rsnte: 0-150 volts {Ft*. 9). Any food multimeter is suitable and can be used to measure AC and DC voltages, check for continuity, short circuits, and grounds. The DC voltmeter leads plug into test jacks on the control chassis. For satis factory operation, the meter will read zero volts with no dame present and steady 90 to 110 volts when the scanner "no" a flame. AC line and load voltages may be checked at the exposed terminals at the bottom of the chassis. Z Test Switch (Figure 10) when in "check" posi tion, electrically discon nects the timer' motor, permitting manual control of timer. NOT?: Removing the A.C. lino plug (In unili is oquipperf) perform! fho lomt oloOruat function a> turning tho tof switch to "chock" petition. 3. Flame Signal Attenua tor. Directly above the vacuum tubes on the chas sis is a recessed pin, which when grounded to the chassis by a clip cord (Fig. 11), will reduce the sensitivity of the flame signal amplifier 40% for test purposes. For Bumor with Pilot Ignition Chocking Scanner Viewing of Pilot Flomo 1. Make sure that control and scanner have been prop erly installed and wired in accordance with the preced ing instructions. Z (Optional) Ground the attenuator pin to the chassis. 3. Plug DC Voltmeter leads into test jacks on control chassis (Red-plus; Black-minus). 4. Tun burner switch on. Let timer progress normally from dial "O'* past dial "X". As it nears dial "1", grasp the AC line plug (located at top left of chassis) ready to withdraw it, on units so equipped. 5. When timer has slightly passed dial "1" and igni tion ia energized, place the test switch is the "check'' position. If pilot flame is not established within 15 sec onds. tun burner switch off. place the test switch in "run" position, tun burner switch back on and repeat from step 4. Repeat as necessary until pilot flame is established. 6. Observe reading on voltmeter. Reading should be *teady, between 90 and 110 volte DC. If the reading fluctuates, it will be necessary to adjust the pilot dame and/or scanner viewing angle. Continue adjustment until steady, correct reading is obtained. Checking Sconnsr Viewing of Main Flam#_____________ 7. Turn burner switch "off, place test switch in "run" position, return burner switch to "on", and let control recycle normally, NOTE; U allot Rom. aotociwd w)rtlln abwi 60 wcmiWi, will lock *vf, mokinj it Inoptratira. It will b* iorf ! lUw tw* Ihr** mmu!t* for lh* (Kormcl oUmont ! <*l on4 I* * lh control manually. Thon rp*al from itp 4. 8. As dial reaches position "2", watch for establish ment of main flame. If flame is not established within about 5 seconds, turn burner switch OFF, then return to ON and allow control to recycle normally for a new lighting trial. NOTI: On an initial Horting attempt, portion! of fuol linot may b* empty and raqwire `'bleeding" lime. It If better te occempllih this with repeoted iherl llghling-lriel period! with intervening purge 'period* ISon te risk prelenged fuel introduction et o lime whon burner edjutlmont hove not boen completed end tho minimum pilot lost hot not boon conducted. De net repeat wmucceiiful lighting attempt! wirheul rechecking burner end pilot adjuitmenh if lighting doet not occur within S second* after fuel Introduction ii veriRed or can be rootenably oiiumed. 9. When miin flame is established, leave burner on and let timer progress until ignition shuts off (either dial position "3" or "dot"). If scanner main flame sighting is reasonably good, the flame relay will stay energized, main flame will stay tit, and the timer will stop at "dot" position. If flame goes out due to insta bility without ignition, readjust burner and repeat tight-off procedure. 10. With step 9 completed and burner remaining tit with timer at "dot" position, readjust burner as neces sary for correct flame size and optimum combustion, then recheck for proper lighting. If scanner is properly sighted, the DC voltmeter will now register a steady 90 volts or> more with pilot flame only and with main flame only. Repeat scanner and btyner adjustments as necessary to obtain this condition if it does not exist initially. 11. With ail steps through 10 satisfactorily completed, remove attenuator connection (if used) and proceed with minimum pilot test. Minimum Filof T*f This test assures that the scanner will not detect flame too small to light off the main flame. It must be made (a) on every new installation, (b) following any change of scanner location or viewing angle, and (c) following replacement of the scanner cell. Do not con duct this test with the attenuator pin grounded! 1Z Repeat step 4. When the timer has slightly passed dial "1" and the pilot is ignited, place the test switch in the "check" position to stop the timer. 13. Reduce the size of the pilot until the flame relay is observed to drop out, then slowly increase the iy of pilot flame just to the point where the flame relay pulls in. This is oiled minimum pilot. (Note Figs. 1Z 13.14). 14. Repeat step 7. When timer reaches dial position "2", watch for main flame to light. CAUTION: If main flame does not ignite in approximately the same time as it did with normal full pilot flame, immediately turn the burner switch OFF! Realign the scanner sight ing tube so that detection requires a larger pilot flame and repeat minimum pilot test Repeat this process until main flame lights reliably on several trials. 15. After minimum pilot test ia completed, increase pilot flame to normal size. /5y-000166 INSTALLATION TESTING Chscking Defection wllh Hot Combuttlon Chomber With aJI the foregoing tests end final burner adjust ments completed, operate the burner (obeerving man ufacturer's warm-up instructions} until combustion chamber is at maximum expected temperature. Recheck for adequate signel with main dame only and with pilot only. If steady output voltage of 90 or more volts DC is not measured at the test jacks, realign scanner sighting to obtain suitable output voltage and then repeat all steps through 15. For Burnar with Spark Ignition (No Filotl Checking Sconnor Viewing of Main Flomo 1. Proceed according to stepe 1, 2 and 3 as outlined previously. 2. Turn burner switch ON. Master relay will pull in and timer will start. 3. As timer reaches dial position 1, watch for main flame to be established. If dame is not established by the time dial position "2" is reached, turn burner switch OFF and then ON again and allow control to recycle normally. CAUTION: If fuel is obcerved to enter combustion chamber and ignition does not occur at once, shut burner switch OFF and check electrode settings. Do not repeat ignition attempts unless a good spark can be observed in a position where the fuel will be readily ignited. 4. If burner ignites and burns properly, DC voltmeter will register a steady 90 volts or more. If voltmeter repsters satisfactorily until ignition shuts off at dial position 3, and then reading becomes unsteady, re adjust burner to obtain stable dame both with and without ignition on. Checking Prfot Ffome Failure Protection 1. Shut off the fuel to the pilot burner. 2. Start the control cycle. 3. After 65 seconds' purge period, the pilot assembly. will be energized. 4. Because no pilot flame is detected, the pilot assem bly will shut off after 10 seconds. The main fuel valve will not be energized. 5. The programming timer will complete its cycle dur ing which rim* the lockout switch will trip, effecting a safety lockout and actuating the alarm (if used). Checking Main Flame Failure Protection 1. Start the burner in the normal manner. 2. After the startup programming has been completed, shut off the main fuel supply. 3. Immediately after the flame fails, the main fuel valve will dose and after approximately 60 seconds the lockout switch will Crip. 4. Following s 15-second post purge or spin-down period, the blower motor will stop, and the alarm will be actuated. 5. The lockout switch may be reset after allowing the thermal element to cool (approximately 2 minutes). txrfWP scrsACTosr msAsmws* piUt Figure 14 000167 SERVICING Trouble! in FP-2 System installations can be readily isjUte-1 by following the approved procedure in the aequence p'ven below. Be/ore beginning any trouble shooting. however, make sure that: 1. Installation and wiring have been made In accord ance with Lnatruetiona. 2. Chaaaia ia securely plugged In and thumbscrew* tightened; test twitch is in "run" position, lockout switch is reset In the following tabulation, troubles appear within boxes and possible causes sre listed below the boxes. CONDITION: Zero voltage at terminals 2 and 4. 1. Disconnect Switch Off. 2. Blown fuse. 3. Broken wire. 4. Incorrect wiring. CONDITION; Insufficient voltage st Terminals 2 and 4. 1. Minimum operating voltage is 102 volts. CONDITION: Zero voltage at terminals 2 and 3. 1. Open limit switch circuit (Pressure, LWCO etc.) .2. Broken wire._ 3. Incorrect wiring. CONDITION: Master relay tRLl) does not pull in. 1. Timer not at dial zero position 2. Lockout switch tripped 3. RL1 armature may be mechanically stuck open 4. Limit or operating controls open 5. Contacts K3-2 or LS-1 open or dirty (Code 32 4 38). Contacts K2-2 or LS-1 open or dirty (Code 27). 6. Inoperative programming control; replace. CONDITION: Master relay pulls in but timer does not start. 1. Contacts RLI-1, K6-1 or K4-2 are dirty or open 2. Timer motor is mechanically bound; check by rotat ing timer dial. 3. Inoperative programming control; replace. (CONDITION: Programming timer starts. Blower I Motor does not start. 1. Insufficient voltage between Terminate 2 and 8. 2. Blown motor fuse. 3. Motor Starter overloads tripped. 4. Burner motor incorrectly wired. 5. Inoperative motor or starter. CONDITION: Modulator motor does not drive to ward open-damper position. 1. Modulator motor not powered. Z Linkage jammed. 3. Incorrect wiring. 4. Contacts RL1-5, K7-2. KS-1 dirty or open. 5. Contacts RL1-6 do not open. 6. Inoperative modulator equipment. CONDITION: Master relay drops out at 10 seconds. 1. Running interlock circuit is not closed. Z Contacts Kl-2, RL1-3 dirty or open. CONDITION: Timer stops between 20 and 40 seconds after dial zero. 1. Purge airflow interlock circuit (8-W) open. CONDITION: Timer stops when "X" appears in timer window. 1. Starting interlock circuit (W-B) open. 2. Flame relay (RL2) holds in due to incorrect scan ner wiring (see page 3) or residual flame in combus tion chamber. 3. K&-3 does not open at 10 seconds (Code 32 4 38 only). 4. RL2-5, K6-2 open or dirty. 5. Inoperative programming control. CONDITION: RLl drops out prior to timer dial position ',2". 1. Momentary or sustained opening of limit circuit f4-3). 2. Running eirflow switch circuit (3-R) open. 3. Contacts RL2-2 or RLl-3, Kl-2 open or dirty (Code (32 4 38). Contacts K3-1 or RLl-3 open or dirty (Code 27). 4. Lockout switch heater open. 5. Lockout switch tripped. CONDITION: Modulator motor does not drive to ward closed-damper position at about 42 seconds. 1. Modulator motor not powered. 2. Linkage jammed. 3. Incorrect or faulty wiring. 4. Contacts RH-5, K7-2,. K8-2 dirty or open. 5. Inoperative modulator equipment CONDITION: Timer dial reaches position "l". Pilot flame ia not established. 1. Insufficient voltage between Terminals 2 and 5 or 6. Z Contacts RLM, K5-1. Kl-2. K+-1 or K7-3 dirty or open. 3. Inoperative gas valve. 4. Inoperative ignition transformer or electrode. 5. Improper electrode setting. 6. Plugged pilot burner. 7. Insufficient gas pressure. 8. Improper pilot burner adjustment. 9. Ignition assembly incorrectly wired. CONDITION: Flame relay (RL2) does not pull in when pilot flame lights. 1- Pilot flame too small. Make sure gas pressure is not less than that specified for the pilot burner. 2. Scanner sight tube obstructed, or scanner lens dirty. 3. Scanner sighting is incorrect. 4. Scanner is incorrectly wired -- correct wiring is white wire to Terminal 15; black wire to Terminal 14. 5. Scanner is too Sot 6. Scanner views hot refractory. 7. Flame relay ia mechanically bound. 8. Inoperative tube or cell, or tubes reversed. 9. Inoperative Scanner. 10. Inoperative control. CONDITION: Timer dial reaches position "2". Main fuel valve stays shut 1. Insufficient voltage between Terminals 2 and 7. 2. Contacts RLl-3, RUM or Kl-1 dirty or open 3. Inoperative valve. 4. Incorrect wiring. 5. Pilot flame not detected 6. Running interlock circuit 3-R open 000168 SERVICING 11 MAINTENANCE FanroN Cell: Estimated life 20,000 hours, when opertied within ambient Lempenhire limits. The scanner lens should be cleaned u often as operating condi tions demand. Tubes: Types 12AX7; 12BH7A; have an estimated life of 10,000 hours. Annual replacement recommended. Replacement tube kits are available from E.C_A. distribution. E.CA. part 7129-62. Contacts: All relay contacts are designed with adequate wiping acdoa for self cleaning under normal condi tions. In atmospheres carrying excessive dust or oily vapors, contacts may require occasional cleaning. Use a burnishing tool or fine grade of crocus cloth for cleaning. Never 01c, sandpaper or apply liquid or unsol spray cieaaer*. Humidity Effects: To protect against high resistance leakage in the electronic drevut resulting from high humidity, it is recommended that the 26RJS Control b left powered continually even when not in opera tion. If it ia necessary to shut down completely for an extended period, power should be turned on for 46 hours before putting the control bade in operation. Rotation: It is recommended that units purchased as spares be rotated, periodically, so that each unit will be placed in operation at least every 90 days, to ascertain that the spare unit is in working order. This will prevent possible deterioration of a unit stored over a period of years. WARRANTY W. guarantee for ooe year from date of shipment to replace or, at our option, to repair any products or parte (hereof which ui lound defective ia material or workmanship or which otherwise tail to eno/ona to (ha contract deecription or to eny warranty, exprow or implied. We make do wurutia whidj extend beyond the deecription of our product oo the taco of our tolas orders nl~i>IThe Purchaser's remedies with respect to any product or part sold by oa shall be limited exclusively to the right to replacement or repair f.o.b. Cambridge, as above provided, la oo evert shell we be liable for mnaeqm or special damages of any nature which may arias ia ooanactioa with such product or part. /fe 000169 1 SUGGESTED SPECIFICATIONS FOR FLAME SAFEGUARD CONTROL FOR AUTOMATIC COMMERCIAL-INDUSTRIAL BURNERS * general 1. Each automatically fired burner shall be equipped with a UL listed and FM approved Electronic Flame Safeguard and Programming Control having the following functions: a. The control shall accomplish a safe start component check during each start, which will prevent the burner from firing under any condition which causes the flame relay to assume and bold its ener gized position due to the presence of an actual flame, a flame simulating component failure or mechanical failure. b. A purge period to purge the combustion chamber and heat exchanger at a minimum rate of 60% of maximum air flow, for sufficient time to accomplish 4 sir transfers of the entire volume shall be provided. The control system shill be interlocked to prevent the burner from firing until the desired purge is accomplished. c. A pilot proving period of not more than 10 sec. prior to energizing the main fuel valve shall be provided. d. Limited trial-for-ignition of main flame, 15 sec. maximum for gas or light oil, 30 sec. maximum for heavy oil shall be provided. e. Safety shutdown shall be accomplished within 4 sec. following a flame failure, loss of minimum combustion air flow or the opqping of any running interlock. f. A post-purge period of not less than 15 sec. shall be accomplished following each normal shutdown and not less than 60 sec. following a safety shutdown. g. The control system shall recycle automatically under control of the operating control, and when power is restored following power failure. Manual reset shall be required following any safety lockout. 2. The control shall permit direct connection of safety limit switches, operating controls, starting interlocks, air flow switches, fuel temperature and pressure switches, running interlocks and lockout alarms. 3. The pilot and main flames shall be monitored by an infrared-sensitive flame scanner sensitive to flame radiation. The scanner shall not be actuated by hot refractory or any other source of infrared radiation. MECHANICAL ond ELECTRICAL 4. The control system shall be designed for 120 volt operation with one side grounded. All switching shall be accomplished in the hot circuit The following shall be furnished: a. The program timing shall be accomplished by cam driven heavy duty switch assembly readily accessible for inspection. The timing periods must not vary more than 5% through an ambient temperature range of 0F to 125F and through a supply voltage range of plus 10% or minus 15% of nominal line voltage. b. The contacts in the fuel valve circuit shall be of a weld-resisUnt tungsten alloy material. c. The safety lockout switch shall be temperature compensated and contain alarm contacts rated at Dot less than 50 va at 120 volts ac. d. The flame relay circuit of the flame safeguard control must incorporate a latch circuit which prevents the flame relay from becoming re-energized following a safety shutdown, until a lockout has occurred and manual reset has initiated a complete restart e. All wiring in the control must be rated for 90 centigrade continuous duty. f. A means for signal attenuation shall be provided for test purposes, and test jacks shall be provided for the direct connection of a DC voltmeter to measure flame relay performance. g. The control chassis shall be of plug in design to facilitate replacement without disconnecting any external wiring. h. The scanner shall mount directly with a threaded fit .ng on a $4" NFT pipe. It shall contain the lead sulfide cell and a focusing lens and be furnishcomplete with a neat insulator. i. Both the scanner and the control shall be rated for <-. ambient temperature limit of 125SF. 5. The flame safeguard control system shall be Fiizyx FP-2. Model 6070. Electronics Corporation of America COMBUSTION CONTROL DIVISION One Memorial Drive - Cambridge. Massachusetts 02142 rci<T 00m: SOSTOH Nfw YOAK . AhiuOCLAXIA ATLANTA CLEVfUNO OETAOIT CniCAOO HOUSTON . LOS ANOELES SAN AAANCJSCO J.aaMfeNM: ECA ICANAOA) LTD.. TOAONTO CCA (OACAT SAITAIN1 LTD. LONOOH (CA (CUAOAC) N.V.. SAUSSELS CCA (AAANCC) SJL. AAAIS CCA (ITALIA) S.A.A.. MILAN CCA lOCUTSCHLAXOl O.m S.H. FAANXALIRT CCA (NCOCALANO) N.V.. AAISTEAOAU 4$ 000120 The Heat Transfer Products Department of American- Standard provides one dependable source for all of your heat transfer needs and requirements. Industry leadership is strived for end maintained through the utilization of time-tested equip rment design, research facilities, coordinated engineering service, years of practical experience, and after-the-sale responsibility. Product specialists are always ready to assist you regardless of the simplicity or complexity of your heat transfer requirements. in 1201 OuOOnj St . Toronto 4 Ontario fepor'T Defif: 40 West 40th St. N*w York. N Y 10018 i-ei'n.nac 2ba; a Join the ranks of some of the world's most discriminating buyers who have been satisfied with American-Standard heat exchanger and boiler products. You are certain to find similar satisfaction whether you're a user, contractor, or specifier. Also, you can benefit from our experience as countless others have--99 years of boiler know-how and 50 years of progress in the heat exchanger industry. CONTACT YOUR NEAREST KEWANEE SALES OFFICE. MARTIN & ASSOCIATES, INC. 101 CHESTNUT STREET, P. 0. BOX 4]J CRANFORD, N. J. 07016 PH 276-8787 Pr5 000073 l tin* m U S A