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BURNER INSTRUCTION MANUAL

FOR GAS AND PRESSURE ATOMIZING OIL FUEL SYSTEMS

P-MODEL

FI FI 8 F OmF

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INTRODUCTION

q Starting a burner is an event which normally culminatesthe effort of severa1 different contractors, manufacturers,

utility and engineering concerns, Sales and factory

representatives, and others.

n In order for the burner to operate safely and meet its

design capabilities, the interfacing fuel, air, electrical,exhaust an.d plant heating contro1 systems must be

properly sized, selected, installed andtested.

Additionally,

all conditions must be such that the heat generated by

the burner can be safely used or wasted without

endangering personnel or equipment.

n It shall be the policy of CIB UNIGAS BURNERS that noresponsibility is assumed by the Company nor any of its

employees for any liability or damages caused by an

inoperable, inadequate or unsafe burner condition which

is the result, either directly or indirectly, of any of the

improper or inadequate conditions describedabove.

n TO insure that a safe and satisfactory installation has

been made, a pre-start inspection is necessary. This

inspection must be performed by an individua1 who is

thoroughly familiar with all aspects of proper boiler/

burner installation and how it interfaces with overall plant

operation.

n Part of this bulletin sets forth major inspection items thatmust be considered.

NOTE

This inspection should-be performed before the burner

start-up specialist is called in. An incomplete or inadequate

installation may require additional time and effort bystart-up personnel and cause an untimely and costly

delay.

n The result of this inspection will often times identify

corrections that must be made prior to start-up as well as

point out potential or long range problems in plant

operation if corrections are not made.

n Burner start-up is serious matter and should not be

viewed as a time for “crowd gathering” by unconcerned,

uninformed or unauthorized personnel. The number of

persons present should be held to an absolute minimum.

n Instruction of operating and other concerned personnel

should be done after the burner has been successfully

fired and adjusted by a qualified service agency or

Commissioning Engineer.

WARNING

Improper servicing of this equipment may create a potential hazard to equipment and operators.

SERVICING MUST BE DONE ONLY BY FULLY TRAINED AND QUALIFIED PERSONNEL.

Before disconnecting or opening up a fuel line and before cleaning or replacing patts of any kind.

W Turn OFF the main manual fuel shutoff valves including pilot gas cock, i f applicable li a multiple fuel burner,

shut OFF al l fuels.

n Turn OFF all electrical disconnects to the burner and any other equipment or systems electrically interlockedwith the burner.

2

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SPECIFICATION OF YOUR BURNER:

SERIAL No

BURNER MODEL

FUELS

2

ELECTRICS MOTOR

CONTROL

FUEL PRESSURES

2

IGNITION GAS

NOTES

3

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ADJUSTMENT PROCEDURE

1. Loosen positioning mechanism.

2. For initial start-up, position air cylinder midway of its stoke.

3. Start the burner and look for optimal cylinder position.

4. Arrange mechanical cam according to positions defined at point 3.

5. ock mechanism.

If positioned too far forward, the main flame may pulsate. If too far tothe rear, the surplus air may cause noisy operation.

Figure 3 1: Adjustment of manual proportioning primary secondary air control.

ITEM 2 ADJUSTMENT OF R INLET LOUVER BOX

DESCRIPTION HOW WORKS

The amount of air available for combustion is controlled by See figure 3-2. Louver opening and trave1 is controlled by

adjustable louvers located in the air box. The louvers are adjusting the linkage mechanism from the actuator to obtain

interconnected through a series of small linkage arms the desired opening and stroke. The actuator drives the

secured to a common drive rod. louvers open or closed as the combustion contro1 programs

the burner firing rate to meet the boiler load

R LOUVRE BOX IS Damper position indicator CT Positioning armRA Regulating boltVB Positioning arm clamp bolt

T Operating rod


1. Use box end or socked wrench to loosen ball joint connector.

2. TO adjust low fire (minimum) air setting, loosen ball joint

connector holding drive rod and manually position louvers to

obtain the desired opening, then retighten connector.

3. TO adjust amount of trave1 (stroke), loosen base of ball-jointconnector located in slotted (louver) actuator arm and reposition

to desired setting, then re-tighten connector.

4. For initial start-up: Position air inlet louvers SO they are

approximately 1/4 inch open.

Figure 3 2: Adjustment of air inlet louvre box

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BURNERIR

AND FUEL ADJUSTMENTS continued

ITEM 6 ADJUSTMENT OF GAS PRESSURE SWlT H S

DESCRIPTION OW IT WORKS

Gas pressure switches are pressure-

actuated electrical See figure 3-6. The pressure switch senses any change in

switching devices designed for safety shutoff when gas gas pressure and, if properly adjusted, will transmit an

pressure are either too low or too high. electrical signal to the automatic shutoff valve andlor other

interlocking devices when an unsafe condition exists, The. burner will then re-eyele or completeiy shut down depending

upon the flame safeguard used. Gas pressure switches are

designed to operate over a specified pressure range;

therefore, each switch must be selected to be compatible

with the burner operating gas pressure and also to obtain

the desired electrical features. .

Gas Pressure Switch

6AS

=4

20

cr

=3

=

40

7

5


p ]

See gas pressure switch manufactures instructionsfor detailedprocedures.

1) For initial Start-up

a. Low Gas pressure Switch-

Adjust to a lower pressurethan that to be experienced for norma1 operation to allowthe burner to be set up.

b. High Gas Pressure Switch-

Adjust to a higher pressurethan that to be experienced for norma1 operation to allowthe burner to be set up.

pi--NOTE]

Final adjustment must be done after the burner has been

test fired. See burner start-up procedure

Figure 3 - 6: Adjustment of gas pressure switches

ITEM 7 ADJUSTMENT OF OlL DRAWER ASSEMBLY

DESCRIPTION OW

IT WORKS

Oil

bumers have an assembly made up of vital oi l and air See Figure 3-7. The oil is forced down the supply tube under

handling components known as the “Oil Drawer Assembly”. high pressure and is atomized into the combustion chamber

Basically, this assemblycontains theoil tube(s), the atomizing by the oil nozzle The air diff user distributes the combustion

nozzle s), the air diffuser with mounting bracket and anoil air through the atomized oil which is then ignited by the gas

distnbutor block and backplate which secures the unit to the pilot ignitor or by an electrical spark if burner has direct spark

burner housing. If the bumer has direct spark oi l ignition, the ignition. On bypassing oil nozzle systems, the excess oil is

ignition electrodes are also a part of this assembly. diverted from the nozzle to the bypassreturn

line.

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1) At back of bumer use Allen key to loosen set screw VI.This will enable the diff userto be re-positioned in relationto the burner head.Generally the diffuser should be positioned as far to therear as possible without impinging the

oil

spray on theinner surface of the burner firing tube.

2) TO adjust the nozzle in relation to the diffuser loosen setscrew V and position nozzle slightly behind diff user - thefinal position cannot be established unt the burner isfired.

Figure 3 - 7: Adjustment of oil drawer assembly

ITEM 8 ADJUSTMENT OF OIL M T RIN VALVE

ES RIPTION

HOW IT WORKS

Oil bumers whichhave

low fire startfuel

contro1 systemsmust deliver oil to the nott at reduced pressure for low fire.This is normally accomplished by diverting a

portion

of theoil

pump delivery thru a bypass return line

to the tank.

The amount ofoil

delivered to thenozzle

versus that

returned to the tank is controlled by a device which limits or meters flow, thus an oil metering valve is commonly used for this purpose.

Most oil metering devices work on the principle of limitingflow by constrictings the area thru which the oil must Pass.In order to vary the orifice area, mechanical movement musttake

place,

thus the oil metering valve requires an actuator to do its job.

By

interconnecting a common actuator to the

combustion contro1 and the oil metering valve, this allowsthe fuel oil to be proportioned in precise ratio to the amountof air available for combustion. This feature is essential onmodulating type fuel contro1 systems.

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The metering valve is adjusted by the position of the ratio

cam-

closing the valve increases the return pressure on the

gauge and increases the burner firing rate, opening the

valve lowers the return pressure and reduces the firing rate.

Normally high firereturn

pressure will be between 18-25 bar

and low fire 5-12 bar.

The return pressure can be adjusted with an Allen key as

shown in the diagram through the full modulating range of

the burner.

Figure 3 8: Adjustment of oil metering valve

BURNERR

AND FUEL ADJUSTMENTS continued

JUSTMIENT OF OIL SUPPLY PRESSURE REGULATOR VALVE (INTEGRAL TO OIL PUMP)

I

2

1

1 Suction2 Return3 Pressure nozzle

4 - Pressure regulator 5-

Gange port (suction)6 - Gange port (pressure)

HOW IT WORKS

Burner oi l pumps are generally identify by the rate at which

they can deliver (GPH), the pressure of the delivery (BAB)

and the speed of rotation (RPM). The pump is usually

capable of delivering more fuel than is required to meet firing

requirements; therefore, the amount of oil delivered to the

nozz must be controlled. This contro1 is accomplished thru

use of an adjustable pressure regulating valve which reduces

flow to the nozzle by causing more oil to be returned to the

tank. Like most regulators, flow is controlled by an adjustable

spring and each regulator has a pressure range over which

it will reliably operate.

ADJUSTMENT OF OIL SUPPLY PRESSURE

The pump is adjusted at the built in pressure regulator as

shown in the diagram.

Remove the cover with a spanner and with a gauge in the

pressure port as shown set the supply pressure between 20

and 25 bar. Replace cover and check supply pressure is

steady through modulating range.

Figure 3 9: Adjustment of oil supply pressure regulator valve

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TART SEQUENCE

Check the electronic ftamesupervision

unit is not in the “lockout” position. In the affirmative,reset

it.

Be certain the temperature and pressure controls are in the “closed” position.

Whenoii

has reached the temperature for starting, blower motor starts and pre-purging begins.

pre-purgin is to to be carried out with maximum air delivery, the burner contro1 circuit turns the air damper to the

max. position, iva the air servocontrol is fully open position, a signal to the electronic contro1 unit starts the pre-purge cycle,

which lasts 30 seconds.

During that period hot oil is circulated as far as the nozzle to ensure good ignition. After pre-purging, the air servocontrol

returns to the fully closed position,SO

that ignition takes place at the minimum firing rate.

Simultaneously the ignition transformer receives voltage and after 3 seconds pre-ignition) the pilot burner ignites and

is proven following which the 3 port valve is energised. Theoil

flows to the atomizing nozzle and ignites, being controlled

by the pressure regulator.

Now the burner is operating at the minimum firing rate (about 30% of the max. firing rate). Afterwards, the air servocontrol

runs to the low flame position and, in case the temperaturecontro1

should be set for the max. firing rate, to the air damper ,

fully open position, while the atomizing nozzte is fed at the max. pressure. which is supplied by the regulator being fully

ctosed via the cam: maximum firing rate is thus reached.

Irrespective of heat required, the contro1 unit continues its programme to the end and retums to its start position for the

next cycle, which will be performed after the burner idle time caused by limit or response switches.

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iiiiii

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GAS IRING ,

1) Isolate the main gas train and operate the burner sequence and ensure that the pilot burner Iights reliably and is capable

of lighting the main flame under all conditions. At the appropriate time the flame safeguard will go to lockout when the

main

ftame does not ignite.

2) With the gas butterfly contro1 valve setto approx 15” open the main gas supply, run the burner sequence, and the burner will ignite on Iow fire.

3) As soon as pratica1 advance the burner to the high fire position and ensure that the gase contro1 valve is fully open - adjust

themain

gas governor to give the rated input by observing the gas meter.

By adjusting the ratio cam for the gas contro1 valve the bumer can now be set throughout its modulating range using

flue gas analysis instruments. Oxygen readings on high fire should be 3-4 and 5-6 % on low fire with zero CO. The

primary air adjustment can also be used for fine regulation of flame shape and excess air.

Adjustment of themain air damper is via the slotted lever.

AIR PRESSURE SWITCH S TTING

Loosen the screw VB. The regulating ring nut is to be setat the bottom of its scale. While the burner is operating, s w y

turn the regulating ring nut clockwise unti1 the burner stops. Then turn the ring back by two tums and re-start the burner.

Should the bumer go to lockout again, turn back by one more full turn.

Tighten the screwVB.

Figure 4.2

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L

DELIVERY ADJUSTMENT

Theoil

systemincludes:

AFuel

oil

Pump

By-passNozrle

(Retum FlowNozzle

C Oil Metering Valve

The diagram illustrates the fuel feeding system of these types of burners, which incorpora a by-pass nozzle with oil flow

regulation in its retum pipe.

The oil supply is varied by acting on the metering valve which determines the oil flow to the nozzle through the pressure

on the return line.

Max oli supply is therefore reached when the pressure in the suction line is about (25 bar oule Type .W2 and the return

is fully closed; min.oil

supply when the retumline

is fully open. Relevant pressure reading in the retumline

are as

follows.

TYPE W2

max. oil supply: 25 bar

min. oil supply: 9 10 bar

Rate of adjustment: 1 to 4

Figure 4.3

46

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R ARE TWO POSSIBILITIES

- The burner has already been adjusted for gas firing.

- The burner must be oil fired only.

TART FL ME S lTlN

upposing the.bumer has already been adjusted for gas firing:

start flame size is to be proportioned to the nozzle size and oil pressure measured at the regulator. Therefore choose

the most suitable nozzle fot the application, SO that during ignition the oil supply should be 113 of the max. one.

‘

When valves open, the pressure measured by the gauge fitted to the regulator must be of5 l

2 bar toallow

min. oil supply

to thenoule.

TO obtain that reading, act on the cam coupled with the air servocontrol.

Ouring start flame setting, it is advisable to interrupt the working cycle.

Air delivery has already been adjusted when burner has been set for gas firing.

Oil and air might not be mixed in the correct proportion, but a futther adjustment of air delivery is negligible as ignitiontime is limited by the interval of the servocontrol between ignition sequence and futther steps.

Before cartying out more operations, trip switch to resume the working cycle.

HIGH FLAME ADJUSTMENT

The servontrol tums the air damper (previously adjusted for gas firing only) to max. delivery. Simultaneously the pressure

egulator controlled by the sector cam is fully closed

and casues an increases in the pressure of the nozzlereturn

flow,

which

evelops max. firing rate.

As air is delivered at a fixed rate during gas firing, it might be necessary to correct max. oil supply. That can be obtained

by acting on the cam which controls the regulator, resulting in a variation of the oil firing rate, unti1 combustion readings

are found to be satisfactory.

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MO UL TING DRIVE MOTOR:

1) The SQM 10 is always set to 90” operation via Cam ‘A’ which is preset at the factory.

2) The low fire position of the burner can be set on Cams ‘C’ or ‘E’ for gas and oil the small indicator arrow shows the position

of the motor in degrees.

3) Cam ‘l3’ is the setting for gas ignition flame.

4) Cam ‘D’ is the setting for oil ignition flame.

Figure 4.5

- HIGH FLAMEIl - IGNITION GAS

Ill - LOW FLAME

IV - IGNITION 01L

V - LOW FLAME OIL

VI - NOT USED

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BY PASSING NOZZLES TYPE FLUIDICS “W2”

Inlet

pressure 25 bar

Turn-down ratio 1: 4

Viscosity 5 cSt

R

500 790” Spray angle

5

Supply 25 bar supp y

357 ps

2

eturn

pressure

I

t ll 1 0 0 kg h

over

bar e

2 0 4 0 6 0 8 0

3 0 0 psi

Return pressure

2 0 0 psi

1 0 0 psi

100 % Output

Figure 4 - 6

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100

90

80

70

60

5 0

40

30

20

10

9

8

7

6

5

4

3

2

1

BURNER GAS THROUGPUT VERSUS HEAD PRESSURE

i

Ill

r I I

I

”

t 1

6 7 8 9 1 0 0 2 3 4 5 6 7 8 9 1 0 0 0 2

THROUGPUT Nm3/ h

Figure 4 - 7

24

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BURNERGASTHROUGPUTVERSUSHEADPRESSURE

MO L F22

I

THROUGPUT Nm3 h

Figure 4 9

3

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HEAVY OIL IRIN ONLY

l L N FILLING

Oi l

in the pre-heater is to be kept at 50” C approx.

Before starting the burner, set the regulating and oil temperature contro1 thermostats at 130” C and 1 IO “C respectively.

These values apply to fuel oil

with viscosity ranging from 25” to 50” E at 50°C.

TO fill the oil line (pre-heater, oil suction, feed to and return from the nozzle) proceed as follows:

1-

Cut offoil

electric heaters via theline

switch (off the contro1 panel).

2-

Link oil, interlock thermostat.

3-

Turn on the cock on the vent pipe of the pre-heater.

4-

Turnfuel

selector to the position “OIL”.

At this point the burner performs a complete start-up cycle. As soon as oil flows out of the vent pipe, throw the line switch

to the “ON” position and turn the cock off. If at the end of the first cycle, when burner goes to lockout and stops, oil has not

filled theline

yet, push reset contro1 button to repeat the cycle.

The line is full up when pressure gauge on the pump indicates about 25 bar., which is the pressure required for proper burner

operation.

TO obtain that reading, loosen or tighten the screw “4”.

A few minutes’ time is admitted to fill the oil line, but a longer time might damage the pump seals.

If the line is not full up, it is necessary to check the suction pipe.

Upon completion of filling, disconnect link and connect start-up thermostat there.

24

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UEL OIL THERMOSTATS

Figure 4.11


140 80

130

@’

I

9 0

0 Q

120 100

110

\

140 8

130

90

{@’

0

120

110

J J

m

TR TCN

Remove the cover which encloses the thermostat and interlock switch (thermostat).

The pointer (2) controls the thermostat setting while the pointer (1) controls the interlock switch (thermostat).

The thermostat pointer (2) should be set at 190” C and then raised or lowered as required.

The coldoil

interlock switch-thermostat is controlled by the pointer (1).

This is setto prevent the burner from starting unti1 a minimum oil temperature is reached and should be set 20 - 25” below

the oil temperature setting on the Heater Contro1 Thermostat.

CAUTION: Do not set the cold oil interlock higher than the oil temperature.

Replace the cover which encloses the thermostat and interlock switch-thermostat.

HEATER CONTROL THERMOSTATHEATER CONTROL THERMOSTAT

TO regulate the thermostat use a screwdriver as shown. The temperature to be set can be determined from viscosityTO regulate the thermostat use a screwdriver as shown. The temperature to be set can be determined from viscosity

iagram. We suggest the actualoil

temperature be set precisely with the burner working using a mercury thermometer iniagram. We suggest the actual oil temperature be set precisely with the burner working using a mercury thermometer in

he pocket.he pocket.

Figure 4.12

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SUNTEC TA

Figure 13

SUCTION HEIGHT : Max. 0 5 bar Vacum 0 4 bar

advised to prevent air separation from oil.

RATEDSPEED : Max. 3600 rpm.

OPERATING VISCOSITY RANGE : 2 8 to 800 cSt.

INLET AND RETURN PRESSURE : Max 5 bar.

5 6

LEGEND:

1 Pump Suction2 Return

3

Nozzle4 Pressure Regulator

5 Vacuum Port

6 Pressure Gauge

7 Electric Heater

OIL LANCE SCHEMATIC

FLOW RETURN NEEDLE

OPERATING

2

3 PORT

AUXILIARY BLOCK HEATER

Figure

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OIL LANCE

NOZZL

E

PRE-PURG

Figure 4 15

N T ON

FI

Figure 4 16

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OIL PRESSURE REGULATOR

f gaseous fuel was not available initiaily, the directions given to set the burnerfor gas firing also apply to oil firing, p rti ul rly

as far as combustion air adjustment is concerned

OIL SUPPLY PRESSURE SETTING

t is to be carried out during pre-purge time by tightening or loosening the socket headed screw RP on the oil pump. For

proper burner operation, the pressure reading indicated by the pressure gauge M must be 25 bar appox.

Figure 4 18

OIL PRESSURE REGULATORS lTIN

The shape given to the blade in the oil sector determines the oil supply to the nozzle.

The figure shows two possible shapes:

: blade shape before start flame setting

L2 : final shape after setting

v

LP

LP

Figure 4 19

RAB-DISTRIBUTOR BLOCK

AUXILIARY HEATER

Figure 4 20

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OIL PIPE CONNECTIONS

CARTRIDGEBELT TYPE HEATER

Figure 42

LEGEND

1 Flow2 Return

3 Needle operating port CARTRIDGE P P HEATER

BELT TYPE HEATER

HASBESTOS HOS Figure 4 22

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THERE ARE TWO POSSIBILITIES:

1 The burner has already been adjusted for gas firing.

2 The burner must beoil

fired only.

START FLAME S TTIN

Supposing the burner has already been adjusted for gas firing:

Start flame size is to be proportioned to the nozzle size and oil pressure measured at the regulator. Therefore choose

the most suitable nozzle for the application, SO that during ignition the oil supply should be one third of the max. one.

When valve opens, the pressure measured by the gauge fitted to the regulator must be of 5-l 2 bar to allow min.oil

supply

to the nozzle.

TO obtain that reading, act on the cam oupled with the air servocontrol.

During start flame setting, it is advisable to interrupt the working cycle.

Air delivery has already been adjusted when has been set for gas firing.Oil and air might not be mixed in the correct proportion but a further adjustment of air delivery is negligible as ignition

time is limited by the intetval of the servocontrol between ignition sequen e and further steps.

HIGH FLAME ADJUSTMENT

The servocontrol turns the air damper (previously adjusted for gas firing only) to max. delivery. Simultaneously the

pressure regulator controlled by the se tor is fully closed and uses an increase in the pressure of the nozzle return

flow, which develops max. firing rate.

As air is delivered at a fixed rate during gas firing, it maight be ne ess ry to correct max. oil supply. That can be obtained

by acting on the cam which controls the regulator resulting in a variation of the oil firing rate, unti1 combustion readings

are found to be satisfactory.

LOW FLAME ADJUSTMENT

Please, refer to gas firing as well.

Oil

supply regulation is carried out by rotating the cam that controls the oil return pressure regualtor unti1 the pressure

reading corresponds to the correct quantity of oil required to burn the air delivered at low flame rating (already adjusted

during gas firing).

3A

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MINIMUM SUPPLY TEMPERATURE TO THE BURNER ACCORDING TO GRADE OF FUEL OIL

100908 0

I I I I I Il

l t MT”

10

98

7

6

i i i i i

1 0 2 0 3 0 4 0 5 0 6 0 8 0

TEMPERATURE “C

Figure 4 23

The burners must be supplied with oil having a min. temperature at the pump inlet according to the above diagram with

relation to the grade of oil being used.

For example: oil being used 7” E, 15” E, 50” E at 50” C the inlet temperature to the pump must be respectively 35” C,

50” C, and 77” C as indicated by the diagram.

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GAS TRAINS

The gas train will be supplied in a straight line arrangement and a special DWG and schematic will be provided with each

contract.

There will effectively be a main gas tr in and a pilot train the pilot can be either natura1 gas or L.P.G.

All components will comply with loca1 standards.

CONTROL PANEL

This is normally supplied as a remote oòr standing unit c/w following

1) Flame safeguard

2) Motor starters fuses

3) Necessary lamps switches

4) Necessary relays timers

5) Modulating ontroller

6) All components wired to a terminal strip7) Pane1 vol tor

A spe ifi schematic and wiring diagram will be provided for each contract.

For any further information please contact our

as shown at the front of this manual.

engineering department at the following address quoting the full specification

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