Industrial combustion LNV Series Installation, Operation And Service Manual Download

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V/LNV SERIES

Installation, Operation, and Service

Manual

DANGER

WARNING

ONLY FACTORY AUTHORIZED BURNER SERVICE
PERSONNEL SHOULD START UP, ADJUST, OR SER-
VICE THIS EQUIPMENT

IC-SA-1511
02/2014

Summary of Contents for LNV Series

Page 1: ...V LNV SERIES Installation Operation and Service Manual DANGER WARNING ONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP ADJUST OR SER VICE THIS EQUIPMENT IC SA 1511 02 2014...

Page 2: ......

Page 3: ...V LNV SERIES Installation Operation and Service Manual Manual Number IC SA 1511 Release Date September 2010 656 10219 000...

Page 4: ...ed No part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means without the prior written consent of Industrial Combustion Industrial Combustion 3...

Page 5: ...t shall be connected to flues having sufficient draft at all times to assure safe and proper operation of the burner The V series burners are designed to burn either gas or light oil No 1 or 2 as defi...

Page 6: ...190 2 8 5 1 2 1 2 15 1 208 230 460 3 V 84 3 8 400 60 0 200 3 1 7 1 2 1 2 1 2 15 5 460 3 V 90 3 9 000 64 3 214 3 5 7 1 2 1 1 2 2 1 2 17 4 460 3 V 100 3 10 000 71 4 238 2 7 10 1 1 2 2 1 2 20 5 460 3 V...

Page 7: ...V 55 3 5 500 39 3 131 2 5 5 3 4 2 19 7 4 208 230 460 3 LNV 60 3 6 000 42 9 143 3 0 5 3 4 2 17 6 4 208 230 460 3 LNV 63 3 6 300 45 0 150 2 0 5 3 4 2 19 4 4 208 230 460 3 LNV 70 3 7 000 50 0 167 2 5 7 1...

Page 8: ...ard K 11 3 4 14 7 16 18 5 8 19 1 4 Center line to burner support standard P 11 3 4 14 7 16 18 5 8 19 1 4 Center line to top inverted R 28 30 5 8 34 3 4 35 1 2 Center line to CL of main gas inlet inver...

Page 9: ...verted R 28 30 5 8 34 3 4 35 1 2 Center line to CL of main gas inlet inverted Q 6 7 8 8 Blast tube dimensions in inches Extension standard C 4 4 4 5 Extension maximum C 5 5 5 6 Diameter D 8 1 4 10 11...

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Page 11: ...tion Air Handling System 1 3 1 4 1 Boiler Room Combustion Air 1 4 1 5 Firing Head 1 5 1 6 Oil System 1 6 1 6 1 Oil System Components 1 6 1 6 2 Operation 1 9 1 7 Gas Handling System 1 9 1 7 1 Main Gas...

Page 12: ...peration 2 8 2 7 3 Suction Line Sizing 2 8 2 7 4 Return Line Sizing 2 8 2 7 5 Two Pipe Multiple Burner System 2 9 2 8 Gas Piping 2 11 2 9 Installation Checklist 2 12 2 10 Firing Modes 2 13 CHAPTER 3 O...

Page 13: ...4 3 Electrical Interference Test 4 2 4 3 1 Gas Fired 4 2 4 3 2 Oil Fired 4 3 4 4 Burner Ignition Adjustment 4 3 4 4 1 Gas Pilot Flame Adjustment 4 3 4 4 2 Gas Pilot Turndown Test 4 3 4 4 3 Direct Spa...

Page 14: ...Combination Gas Oil Burner Adjustment 4 20 4 7 3 Full Modulation Combination Gas Oil Burner Adjustment 4 20 4 8 Modulation Control 4 20 4 8 1 Linkage Control Adjustment 4 20 4 8 2 Cam Trim Adjustment...

Page 15: ...tem 5 6 5 14 1 Electric Motors 5 6 5 15 Checking Flame Failure 5 6 5 15 1 Pilot Flame Failure 5 6 5 15 2 Failure to Light Main Flame 5 7 5 15 3 Loss of Flame 5 7 5 16 Extended Shutdown 5 7 5 17 Mainte...

Page 16: ...4 FGR Control Valve 7 3 7 4 1 Low NOx Full Modulation Combination Gas Oil Burner Adjustment 7 4 7 5 Air FGR Damper Assembly 7 5 7 6 Stack Temperature Interlock 7 5 7 7 Blast Tube Temperature Interlock...

Page 17: ...s to understand the operations and procedures described in this manual 1 2 Description The Industrial Combustion V series burners are designed to operate with gas and light oil The burners are designe...

Page 18: ...the firing fuel Off position Burner is off Oil position Selects oil as the firing fuel Control Circuit Breaker Supplementary low overcurrent protection only No larger than 15 amps Auto Manual Modulati...

Page 19: ...fire rate to prevent thermal shock until conditions are suitable for high fire Full modulation burners are capable of firing at any rate between the burner s low and high fire limits For single point...

Page 20: ...e boiler room preferably 7 foot or lower This allows air to sweep the length of the boiler A boiler room vent fan is not recommended Under certain conditions these fans can cause a light vacuum and st...

Page 21: ...igure 1 1 shows a a radial spud firing head typically used on watertube applications while Figure 1 2 illustrates a typical arrangement for firetube applications FIGURE 1 1 Burner Housing Watertube Ap...

Page 22: ...a heat exchanger s required input Models V13 34 are supplied with simplex nozzles return flow nozzles optional on V25 34 Models V35 168 are supplied with return flow nozzles Nozzle Adapter A nozzle ad...

Page 23: ...e V13 34 FIGURE 1 5 LHL Oil System with Integral Pump Return Flow Nozzle V13 55 OIL SUPPLY OIL RETURN TO TANK FUEL UNIT N C OIL VALVES OIL NOZZLE OIL PRESSURE REGULATOR N O OIL VALVE 656 10211 000 OIL...

Page 24: ...n Oil System with Integral Pump Return Flow Nozzle V13 55 MODULATING MOTOR FUEL UNIT PRESSURE TAP FUEL UNIT OIL METERING VALVE OIL NOZZLE OIL RETURN TO TANK OIL PRESSURE SWITCH OIL SUPPLY 656 10211 00...

Page 25: ...opening and allowing more oil to return to the supply tank Conversely at high fire the valve is closed forcing all oil to exit the spray nozzle On LHO LHL units bypass piping routes most of the oil b...

Page 26: ...ecified pressure required at the burner manifold Input is set by main gas pressure regulator adjustment Main Gas Cocks Used for manual shutoff of the gas supply upstream of the pressure regulator A se...

Page 27: ...IC SA 1511 02 2014 V LNV Series Manual 1 11 Introduction FIGURE 1 9 Typical Gas Train for On Off System V13 25 FIGURE 1 10 Typical Gas Train for LHO System V13 34...

Page 28: ...duction 1 12 IC SA 1511 02 2014 V LNV Series Manual FIGURE 1 11 Typical Gas Train for Full Modulation System V13 34 FIGURE 1 12 Typical Gas Train for LHO LHL Systems V35 63 Full Modulation Systems V35...

Page 29: ...automatic gas valve s cannot be energized unless the combustion air proving switch is closed The low and high gas pressure switches must be closed to prove proper gas pressure A normally open vent va...

Page 30: ......

Page 31: ...lied by the burner forced draft blower providing adequate air for any normal combustion condition Since draft control is essential to maximum efficiency a draft regulator may be required when the vess...

Page 32: ...4 Combustion Chamber Recommendations 2 4 1 Combustion Chamber Drawings Firetube Boiler Application FIGURE 2 1 Standard Configuration for Firetube Boiler FIGURE 2 2 Inverted Configuration for Firetube...

Page 33: ...8 11 37 56 25 6 28 8 11 37 56 30 6 28 9 11 37 56 34 6 28 10 11 37 56 35 6 31 10 14 40 62 40 6 31 11 14 40 62 42 6 31 11 14 40 62 45 6 31 12 14 40 62 50 6 31 12 14 40 62 54 6 31 13 14 40 62 55 6 31 13...

Page 34: ...rtube Cast Iron Boiler Application s FIGURE 2 3 Standard Configuration for Watertube Cast Iron Boiler FIGURE 2 4 Inverted Configuration for Watertube Cast Iron Boiler Q A L C C MIN E D STANDARD FIREBR...

Page 35: ...4 15 28 12 11 37 6 63 26 36 35 21 31 13 5 14 40 6 63 30 62 40 21 31 13 5 14 40 6 63 30 62 42 21 31 13 5 14 40 6 63 30 62 45 21 31 13 5 14 40 6 63 30 62 50 21 31 13 5 14 40 6 63 30 62 54 21 31 13 5 14...

Page 36: ...mperature bonding mortar with provision for expansion 2 5 Installation Prepare the boiler front plate as follows 1 Determine burner mounting height Locate and scribe a level horizontal centerline acro...

Page 37: ...d be packed with Kaiser Refractory Mono T 9 Airset or equal within two hours after coating the dry oven with Trowleze From inside the furnace ram the plastic refractory from the front to the rear para...

Page 38: ...the tank to the pump 2 Pressure drop through valves fittings strainers etc 3 The friction loss due to oil flow This loss varies with a Quantity of oil pumped gph b Length of suction line feet c Diamet...

Page 39: ...inlet pressure is above 3 psi Figure 2 9 shows an installation using a day tank A pump supplies oil to the day tank Figure 2 10 shows a flooded loop system The circulating pump is sized according to...

Page 40: ...Installation 2 10 IC SA 1511 02 2014 V LNV Series Manual FIGURE 2 7 Multiple Burners with Separate Suction Lines FIGURE 2 8 Typical Oil Loop for Multiple Burners with Transfer Pump...

Page 41: ...stem 2 8 Gas Piping Refer to Figures 1 9 through 1 12 for typical gas piping arrangements Normally the control train is ordered to suit a particular code or insurance regulation such as UL cUL FM or G...

Page 42: ...stallation Checklist 1 All burners are carefully assembled and tested at the factory but before being placed in service all connectors should again be checked for looseness caused during shipment Chec...

Page 43: ...with on off units is adjusted at the time the burner is installed and is fixed in place The open damper position allows a fixed rate of air flow during all aspects of burner operation while the blowe...

Page 44: ...ion Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing...

Page 45: ...gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valve s low fire setting Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure a...

Page 46: ...e manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s low pressure...

Page 47: ...to the manifold is metered based on the butterfly valves low fire setting Safety shut off valves open allowing oil to flow from pump to nozzle Oil pressure at the nozzle is based on the pump s low pr...

Page 48: ...s now ready for startup Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valve low fire setting Safety shut off va...

Page 49: ...lating actuators Also optional is an actuator with dual low fire start switch positions for improved turn down in dual fuel situations None On models with a simplex nozzle oil is diverted from the sup...

Page 50: ...oving switch The burner is now ready for startup Valves open To prevent a surge the primary gas valve opens at a slowed rate Gas flow to the manifold is metered based on the butterfly valve low fire s...

Page 51: ...ting actuators Also optional is an actuator with dual low fire start switch positions for improved turndown in dual fuel situations None On models with a simplex nozzle oil is diverted from the supply...

Page 52: ...g less the volume of oil returning through the metering valve RUN MODULATE Damper is driven by its parallel positioning actuator to a firing rate position as determined by the parallel positioning con...

Page 53: ...trol at the desired temperature or pressure Burner For protection in shipment the flame safeguard control chassis is shipped unmounted Check all screw connections before attaching the flame safeguard...

Page 54: ...line undersized oil line or excessive lift When there is a positive head of oil at the fuel unit either from a gravity or by pump circulation the pressure must not exceed 3 psi at the fuel unit sucti...

Page 55: ...al changes including air temperature humidity barometric pressure and fuel property changes Refer to the nameplate inside the control panel for minimum and maximum fuel input ratings Refer to Chapter...

Page 56: ...is regulated by adjusting the pressure setting of the pilot regulator Normal setting is 4 to 6 W C when the pilot is burning The flame must be sufficient to be proven by the flame detector and ignite...

Page 57: ...er motor stop Burner is ready for startup on the next call for heat 3 6 Manual Shutdown 1 Turn selector switch to the off position The burner shuts down in Automatic Shutdown as above 2 When the burne...

Page 58: ...fire position 6 Open the gas pilot cock 7 Set the ON OFF switch to ON The burner will start and pre purge After pre purge the ignition transformer and the gas pilot solenoid are energized Before proce...

Page 59: ...Vent fuel vapors from the combustion chamber after each unsuccessful light off attempt Set the gas low fire rate by adjusting the butterfly valve and air linkage Refer to the adjustment section of thi...

Page 60: ...ozzle In high fire the oil metering valve should be in the fully closed position and the fuel oil pressure should be about 300 psi Check high fire at this point using combustion instruments High fire...

Page 61: ...9 5 10 5 12 4 13 7 2 5 12 1 10 3 12 0 13 5 3 0 15 0 10 0 11 7 13 0 3 5 18 0 9 6 11 5 12 6 High Fire Range 4 0 21 0 9 4 11 2 12 3 4 5 24 5 9 1 10 8 11 9 5 0 28 1 8 8 10 4 11 6 Mid Fire Range 5 5 31 9...

Page 62: ...post purge the blower motor is de energized The programmer returns to its starting position and stops The unit is ready to restart Abnormal shutdown might result from motor overload flame outage low...

Page 63: ...although it may help in making preliminary settings The proper settings of air fuel ratios must be determined by flue gas analysis Combustion gas analysis indicates the air to fuel ratio and the degre...

Page 64: ...ometer to measure draft pressures 4 Smoke spot tester for oil burners and CO analyzer for gas fired units 5 Voltmeter Ammeter 6 Stack thermometer and thermocouples 4 2 4 Gas Adjustments Low fire combu...

Page 65: ...detector and ignite the main flame To adjust pilot gas pressure unscrew regulator cap and turn the adjusting screw in or out Although it is possible to visibly adjust the size of the pilot flame obta...

Page 66: ...GURE 4 1 Direct Spark Ignition Oil Only VL V13 55 4 4 4 Burner Pilot Settings To ensure reliable and safe burner performance the location and gap setting of the electrodes and the relative positions o...

Page 67: ...2 Slide the diffuser clamp along the length of the burner pipe until the correct dimension is obtained 3 Tighten the diffuser clamp securely to the burner pipe Apply a lock tight type compound to the...

Page 68: ...Oil V13 34 Firetube 26 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 26 REAR FACE OF DIFFUS...

Page 69: ...ACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 26 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFL...

Page 70: ...for VLG Gas Oil V60 110 Firetube FIGURE 4 11 Drawer Assembly for VG Gas Only V120 168 Firetube 16 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 656 10214 000 00 FROM NOZZLE TIP TO FRONT FACE OF D...

Page 71: ...4 6 Drawer Assemblies for Watertube Cast Iron Boiler Applications FIGURE 4 13 Drawer Assembly for VG Gas Only V13 34 Watertube Cast Iron 15 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 00 FROM N...

Page 72: ...t Iron 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 1 89 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 7 16 FROM CENTER OF OIL NOZZLE TIP TO BOTTOM ED...

Page 73: ...ube Cast Iron 25 FROM NOZZLE TIP TO REAR FACE OF DIFFUSER 1 89 REAR FACE OF DIFFUSER TO FRONT FACE OF 25 NOZZLE TIP TO OUTER EDGE OF ELECTRODE WIRES 7 16 FROM CENTER OF OIL NOZZLE TIP TO BOTTOM EDGE O...

Page 74: ...rtube Cast Iron FIGURE 4 22 Drawer Assembly for VLG Gas Oil V120 168 Watertube Cast Iron 1 83 REAR FACE OF DIFFUSER TO FRONT FACE OF AIR BAFFLE 00 FROM NOZZLE TIP TO FRONT FACE OF DIFFUSER 656 10215 0...

Page 75: ...vations up to 2000 feet above sea level 4 5 2 Gas Flow The volume of gas is measured in cubic feet as determined by a meter reading The gas flow rate required depends on the heating value Btu cu ft Th...

Page 76: ...rther adjusting Recheck low fire and adjust if necessary Proper setting of the air fuel ratios at all rates must be determined by combustion analysis See Section 4 2 of this chapter for additional inf...

Page 77: ...pressure downstream of the regulator Make sure they are in accordance with the regulator specifications The gas pressure required at the manifold is the pressure that is required to fire the burner at...

Page 78: ...8 At each point allow the burner to operate for a few minutes before recording the O2 CO and pressure readings Observe that the O2 and CO levels remain within an acceptable limit Adjust the pressure r...

Page 79: ...ues modulating back to low fire and adjust accordingly 4 6 Oil System Refer to the burner data plate located inside the control panel door The nameplate will list the following burner information burn...

Page 80: ...h The burner should be adjusted to provide the correct amount of fuel flow at a constant rate at high fire position as indicated on the burner data plate located inside the control panel 5 Tighten all...

Page 81: ...th the cam trim option adjust the cam screws throughout the range to obtain correct O2 and CO levels Continue to do this until the burner reaches high fire the potentiometer is at the OPEN position 7...

Page 82: ...ators low and high pressures for models V13 34 4 7 3 Full Modulation Combination Gas Oil Burner Adjustment 1 Set the MANUAL AUTO switch to the MANUAL position 2 Position the manual flame control poten...

Page 83: ...tain correct flue gas readings The adjustment is made to the metering cam by means of the 14 adjusting screws which are turned in clockwise from the hex socket end to increase the flow of fuel and out...

Page 84: ...throughout the firing range 4 9 Air and Fuel Controls 4 9 1 Air Flow Control The V series burners have a two blade air shutter design Both blades are coupled together and are attached to the modulati...

Page 85: ...s turndown performance may be restricted by the excess air and fuel turndown levels set for oil combustion Excess air O2 and unburned fuel CO levels in boiler flue gases are used to determine combusti...

Page 86: ...Adjustments 4 24 IC SA 1511 02 2014 V LNV Series Manual FIGURE 4 26 Front and Rear Shutters OPEN OPEN FRONT AIR SHUTTER REAR AIR SHUTTER...

Page 87: ...le maintenance beyond regular inspection Examine electrical connections Keep the controls clean Remove any dust from the interior of the control Covers should be left on controls at all times Keep the...

Page 88: ...afety lockout upon failure to ignite the pilot or he main flame and upon loss of flame Each of these conditions should be checked on a scheduled basis The safety check procedures are contained in the...

Page 89: ...r assembly access cover 4 After making note of where the bolts are located in relationship to the access cover slots remove the drawer assembly access cover bolts Pull the drawer partially out of the...

Page 90: ...true 5 7 Flame Scanner The scanner must be clean Even a small amount of contamination will reduce the flame signal Wipe the scanner lens with a clean soft cloth Check pilot and flame signal strength T...

Page 91: ...inkages Make sure all connections are tight Adjust if necessary Perform a combustion test as explained in Chapter 4 and readjust the burner if necessary 5 11 Burner Mounting Inspection The seal betwee...

Page 92: ...systems applicable to this equipment complete descriptions of all burner electrical systems are beyond the scope of this manual An individual electrical schematic drawing is shipped with each burner a...

Page 93: ...tion shut off the main burner fuel supply to extinguish main flame 2 The fuel valves will be de energized and the relay will signal the condition within four seconds The control will then lock out on...

Page 94: ...d in log Flame Signal Strength Controls Operator Read and log the flame signal for both pilot and main flame Notify service if readings are very high very low or fluctuating Linkages Operator Check al...

Page 95: ...has the capability to self diagnose and to display a code or message that indicates the failure condition Refer to the control bulletin for specifics and suggested remedies Familiarity with the progra...

Page 96: ...tor switch to the OFF position Shut off the main manual fuel shutoff valves on the fuel supply line The unit can also be shut down with the main electrical power disconnect Inspect the burner carefull...

Page 97: ...ir proving switch and high fire limit switch 4 High or low gas pressure investigate and repair No Ignition 1 Lack of spark a Electrode grounded or porcelain cracked b Improper electrode setting c Loos...

Page 98: ...ulating motor 4 Defective modulating control 5 Binding or loose linkages cams setscrews etc Shutdown Occurs During Firing 1 Loss or stoppage of fuel supply 2 Defective fuel valve loose electrical conn...

Page 99: ...e to open or close during pre purge or close on burner shut down a Motor defective b Loose electrical connection c Damper motor transformer defective 4 Motor does not operate on demand a Manual automa...

Page 100: ......

Page 101: ...ncoming fresh air An electrically actuated damper controls the flow of FGR to fine tune the FGR fresh air ratio Ducting from the stack or boiler to the burner is done by others All FGR duct piping sho...

Page 102: ...FIGURE 7 2 FGR Connection to Boiler Top View Minimal Pipe Size Schedule 10 Pipe in Burner Model Maximum Feet From Burner to Boiler Stack 20 30 40 50 75 100 150 200 LNV SIZE 1 4 4 4 4 6 6 6 6 LNV SIZE...

Page 103: ...ing to the combustion zone FIGURE 7 3 FGR Shutoff Valve 7 4 FGR Control Valve The FGR control valve is mounted to the FGR damper on the burner A burner mounted actuator with linkage connections coordi...

Page 104: ...ppm NOx levels 4 Monitor O2 and CO levels during this process The introduction of FGR into the combustion chamber will lower the flue O2 levels Too much FGR may induce high levels of CO in the flue g...

Page 105: ...n air mixed with flue gas is passed on through the blast tube to the combustion zone 7 6 Stack Temperature Interlock An optional stack temperature interlock device monitors flue gas temperature in the...

Page 106: ...LNV Series FGR System 7 6 IC SA 1511 02 2014 V LNV Series Manual FIGURE 7 6 Temperature Interlocks...

Page 107: ...ease scale deposits or other contaminants in the equipment Warranty Adjustment Buyer must make claim of any breach of any warranty by written notice to the Company s home office within thirty 30 days...

Page 108: ...rth Buyer s exclusive remedy and the extent of the Company s liability for breach of implied if any and express warranties representations instructions or defects from any cause in connection with the...

Page 109: ...Temp F Operating Limit O2 High Limit CO Operating Control CO PPM Stack Temp Interlock NOx PPM Flame Failure Smoke Bacharach Combustion Air Switch Combustion Eff High Purge Switch Stack Draft W C Low F...

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