ACCESS COMBUSTION...2. Slowly open incoming gas valve (2) and measure incoming gas pressure. a. Close the incoming gas valve if main gas pressure exceeds maximum pressure ratings on

Burner Model R

INSTALLATION, OPERATION, AND SERVICE MANUAL

ACCESS

COMBUSTION

Copyright 2019 © by Access Combustion. All rights reserved. This document is a proprietary property of Access Combustion, LLC.

The manual is not to be disclosed to others without consent of Access Combustion.

Unauthorized use is expressly forbidden.

For Information, Service, or Repair Please Contact: Access Combustion.

919-576-7100

[email protected] www.accessburner.com

WARNING: Only Factory Authorized Burner Service Personnel Should Start, Adjust, or Service This Equipment

http://www.accessburner.com/

ACCESS COMBUSTION

WARNING:

Only authorized burner service personnel should start, adjust, or service this equipment!

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TABLE OF CONTENTS Installation, Operation, and Service Manual ............................................................................................................. 1

Section I: General Safety and Warnings ................................................................................................................. 3

Section II: Installation Checklist ................................................................................................................................ 4

Section III: Burner Installation ................................................................................................................................... 5

Burner Block Installation and Drying ......................................................................................................................... 5

Burner mounting ....................................................................................................................................................... 5

Pilot and Ignition System ........................................................................................................................................... 6

Typical Gas Train ........................................................................................................................................................ 7

Gas Train Pressure Test ............................................................................................................................................. 8

Burner Sequence of Operation .................................................................................................................................. 9

Section IV: Burner Commissioning......................................................................................................................... 10

Pilot Commissioning ................................................................................................................................................ 10

Main Flame Commissioning ..................................................................................................................................... 11

Ignition Troubleshooting ......................................................................................................................................... 12

TABLE OF FIGURES

Figure 1 Burner Installation ........................................................................................................................................... 5

Figure 2 Igniter Setting .................................................................................................................................................. 6

Figure 3 TYPICAL GAS TRAIN .......................................................................................................................................... 7

Figure 4 PILOT/MAIN GAS REGULATOR ......................................................................................................................... 7

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SECTION I: GENERAL SAFETY AND WARNINGS

• Do not attempt to operate the burner without first familiarizing yourself with burner operating

instructions!

• This burner must only be serviced by fully trained and qualified personnel.

• Do not operate this equipment until the equipment has passed all safety inspections required by

your area.

• Before performing any service work on the burner, turn OFF ALL manual fuel shut offs valves,

including pilot gas shutoff valve, and turn OFF ALL electrical power to the appliance and any

other equipment that is electrically interlocked with the appliance.

• Do not bypass flame management sequencing and safety interlocks!

• This burner utilizes fuel that is flammable and potentially explosive. If smell of fuel is present

evacuate the area and call gas supplier and/or fire department.

• Do not enter a furnace, boiler or fired vessel.

• Use and storage of gasoline or other flammable liquids and vapors in open containers in the

vicinity of this burner is hazardous and could result in a fire or explosion.

• DO NOT use Teflon tape or components with Teflon as an oil or gas pipe sealant as Teflon can

cause valves to fail, creating a SAFETY HAZARD. All manufacturer warranties are voided and all

liability rests with the INSTALLER when evidence of Teflon is found. ONLY use a pipe sealant

approved by the Underwriters Laboratories for assembly of oil and gas piping.

• Castable refractory dust contains cristabolite and / or crystalline silica and the ceramic fiber

refractory contains fibers, all of which may be carcinogenic. Use proper and approved respiratory

protective equipment, as well as any other necessary personal protective equipment required to

avoid exposure.

• If this appliance is not installed, vented, operated and maintained properly per manufacture

instructions, it could expose you to hazardous substances in the fuel or hazardous fumes from

fuel combustion which can cause death or serious illness and are known by the State of

California to cause cancer, birth defects and reproductive harm.

• This manual has been prepared to assist in installation, operation and maintenance of your

burner. Only appropriately trained and qualified personnel should be permitted to operate this

equipment. The instructions contained herein should be read carefully before operating the

equipment.

• Improper operation of the equipment will result in injury to persons or loss of life and damage to

equipment. Access Combustion shall assume no responsibility for the improper or unsafe

operation of the burner due to failure to adequately address the concerns above.

• The information contained in this manual is to be used as a guide ONLY and may be superseded

by project specific specifications and drawings.

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SECTION II: INSTALLATION CHECKLIST

Warning: Make sure the checklist is reviewed and verified before proceeding to Burner Commissioning section.

Burner Check List

Is the burner securely connected to the heat exchanger?

Is the dry oven properly installed and secured inside the heat exchanger?

Was the electrical wiring verified?

Were all motors checked for rotation?

Are all gas train components installed, and have been properly selected, sized and installed per appropriate installation and wiring drawings and instructions?

For gas trains requiring venting, are the vent lines properly sized and installed?

Are gas train piping and components tested for leaks and are they gas tight?

Have the gas lines been purged?

Is the proper gas pressure available at the inlet to the fuel train?

Are there adequate provisions for the combustion air installed?

Is the burner combustion air inlet free from obstruction?

Heat Exchanger Check list

Is the heat exchanger filed with sufficient heating medium (water, oil, glycol, etc.)?

Are the heat exchanger safety limits verified, (low fluid cut-off, high temperature shutdown, etc.)?

Are any connected load circulation systems properly installed and operation verified?

Is the heat exchanger stack properly installed?

Is the heat exchanger stack unobstructed to allow for safe relief of the hot flue gasses generated by the burner?

If draft control equipment is required, is it installed and operation verified?

Are all specified auxiliary equipment installed properly? This may include thermostats, flow switches or others.

At a minimum, the following interested parties should be notified of the burner startup date. o Equipment Owner’s Representative o Mechanical Contractor’s Representative o Electrical Contractor’s Representative o Service Organization’s Representative o Burner Manufacturer’s Representative o Heater Manufacturer’s Representative

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SECTION III: BURNER INSTALLATION

BURNER BLOCK INSTALLATION AND DRYING

The burner block provided with Model R burner is made of castable refractory. To insure desired block performance, care must be taken during the dry out or bake out time. The provided burner block is air dry only and must be dry out at elevated temperature. The ideal heat source for the drying of the refractory is the heater itself. Block dry out should be done during the initial burner commission on the heater.

Refractory dry out consist of slow temperature ramp up rate and temperature hold time.

1. Using normal heater startup procedures, monitor and raise the exit gas temperature of the heater 77ºF (25 ºC) per hour until the temperature reaches approximately 194ºF (90 ºC). Fire the burner at low firing rate only.

2. Hold the temperature at the gas outlet based on the hold time rule that 1 hour is required for every inch (25.5mm) of thickness of refractory to be dried.

3. Raise the exit gas temperature of the heater 77ºF (25 ºC) per hour until the temperature reaches approximately 700ºF (371 ºC). Start modulating the burner to mid fire rate.

4. Hold the temperature at the gas outlet for the same period as in step two. 5. Monitor the process outlet temperature, do not overtempt process fluid temp. 6. Raise the exit gas temperature of the heater 77ºF (25 ºC) per hour until the temperature at the heater

reaches normal expected operating temperature.

BURNER MOUNTING

FIGURE 1 BURNER INSTALLATION

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Set distance X to 1/8inch (3.2mm)

PILOT AND IGNITION SYSTEM

Model R Burners are equipped with an integrated piloted design. Pilot shall be used only for ignition of the main

flame (interrupted pilot). For a direct spark burner configuration start the burner at low fire settings only. Ideal pilot

gas flow rate should be between 60,000BTU/hr to 100,000BTU/hr.

Use minimally 5000V ignition transformer for spark generation.

Igniter should spark to the gas tip nozzle only. Arc should create sufficient light to be visible through the observation

window. To set the correct gap between the igniter and the gas nozzle (distance X) move the igniter into the burner

until the igniter hits the gas nozzle. Mark the location on the ceramic and pull the igniter back 1/8 inch (3.2mm).

Tighten the ceramic in place. Do not overtighten the ceramic, as the ceramic can brake.

FIGURE 2 IGNITER SETTING

If piloted ignition is used, locate the pilot valve as close as possible to the pilot burner gas inlet.

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TYPICAL GAS TRAIN

FIGURE 3 TYPICAL GAS TRAIN

FIGURE 4 PILOT/MAIN GAS REGULATOR

To adjust gas pressure, remove Seal Cap (Item 1) and turn Adjusting Screw (Item 7) clockwise for more pressure and

counterclockwise for less gas pressure. Use screwdriver to turn Adjusting Screw. Always reinstall Seal Cap to prevent

tampering and dirt or moisture accumulation.

2 1

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GAS TRAIN PRESSURE TEST

Warning: Incoming main gas pressure must be lower than the maximum rated pressure on all gas train components. Warning: If smell of fuel is present evacuate the area and call gas supplier and/or fire department.

1. Referring to Figure 3, make sure Leak Test Valve (1) is closed. 2. Slowly open incoming gas valve (2) and measure incoming gas pressure.

a. Close the incoming gas valve if main gas pressure exceeds maximum pressure ratings on the gas train.

b. Contact your local gas supply company for pressure adjustment. c. Contact your Heater Representative.

3. Check for gas leaks between main incoming gas and valve (2) on the gas train by either performing a bubble test or measuring gas pressure.

a. Refer to your local gas code guidelines for gas leak test and gas test procedure. 4. Main Gas train leak test can only be performed during burner operation.

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BURNER SEQUENCE OF OPERATION Refer to a Specific Burner Management System (BMS) Manual for detailed information and control sequence timing information. 1. Burner is energized when demand is activated by heat exchanger limit switch. 2. Burner motor starts. 3. Air damper valve opens. 4. A pre-ignition air purge sequence begins. 5. Air purge time depends on the control type and is intended to provide 4 to 5 volume air exchanges before

starting the burner. 6. Air damper valve closes. 7. Ignition Transformer is energized. 8. Pilot solenoid valve opens. 9. Pilot flame is detected by the BMS. 10. Ignition Transformer is de-energized. 11. Main Solenoid valve opens. 12. Pilot Solenoid valve is de-energized. 13. Main flame is detected by the BMS. 14. Burner is ready for modulation. If demand is interrupted 15. Main Solenoid valve are de-energized. 16. Air damper valve opens. 17. A post-ignition air purge sequence begins. 18. Air purge time depends on the control type. 19. Air damper valve closes. 20. Blower is de-energized. 21. Burner remains in standby mode. 22. If a fault occurs during the sequence of operation an error message will be displayed on the BMS. 23. Refer to the specific BMS manual for additional information.

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SECTION IV: BURNER COMMISSIONING

Warning! Make sure Burner Installation Check list has been completed! Warning! Make sure all steps were followed in accordance to the manual and local codes before commissioning the burner. Warning! Make sure proper combustion instruments (emission analyzers) are available and connected during the duration burner commissioning!

PILOT COMMISSIONING Follow the steps below if burner is equipped with a pilot gas train. If burner lacks pilot gas train and is configured as a Direct Spark Ignition System, skip Pilot Commissioning Section and move on to Main Flame Commissioning Section.

1. Referring to Figure 3, make sure Leak Test Valve (1) is CLOSED and remains closed thought the duration of this test.

2. Make sure pilot manual valve is OPEN 3. Open the manual shut-off valve (2) 4. Allow heat exchanger limit switch to close and energize the burner (demand). 5. Burner motor should start. 6. Air damper should drive to open. 7. A pre-ignition air purge sequence begins. 8. After pre-ignition purge air damper valve should close. 9. Ignition Transformer should energize. 10. Pilot solenoid valve should open. 11. At this point the BMS system should sense the pilot flame. The BMS system should show a confirmed pilot

flame. Refer to the specific BMS manual for details on how this will be reported. 12. Verify pilot signal strength before proceeding to the next step.

a. Refer to the specific BMS manual for pilot flame signal strength test. 13. Adjust pilot pressure (see Figure 4) by removing Seal Cap (item 1) and turn Adjusting Screw (item 7).

a. For more pressure turn Adjusting Screw IN (clockwise). b. For less pressure turn Adjusting Screw OUT (counterclockwise).

14. If pilot flame signal is weak please refer to pilot troubleshooting section in the manual. 15. Contact Access Combustion for resolution.

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MAIN FLAME COMMISSIONING

Caution! Make sure pilot flame signal is within BMS operation range before proceeding to the main flame test.

1. Make sure Leak Test Valve (1) is OPEN. 2. Make sure pilot manual valve is OPEN 3. Open the manual shut-off valve (2) 4. Allow heat exchanger limit switch to close and energize the burner (demand). 5. Burner motor should start. 6. Air damper should drive to open. 7. A pre-ignition air purge sequence begins. 8. After pre-ignition purge air damper valve should close. 9. On Burners equipped with pilot gas train.

a. Ignition Transformer should energize. b. Pilot solenoid valve should open. c. The BMS system should show a confirmed pilot flame. Refer to the specific BMS manual for details on

how this will be reported. d. Ignition Transformer should de-energize. e. Main gas valves should open followed by main flame ignition. f. At this point the BMS system should sense the main flame. Refer to the specific BMS manual for details

on how this will be reported. g. Pilot valve should de-energize.

10. On Burners configured to a Direct Spark Ignition System. a. Ignition Transformer should energies. b. Main gas valves should open followed by main flame ignition. c. Ignition Transformer should de-energize. d. At this point the BMS system should sense the main flame. Refer to the specific BMS manual for details

on how this will be reported. 11. Burner should remain lit.

• Verify main flame signal.

• Verify CO and O2 emissions levels before changing burner setting.

• If the flame appears weak, slightly open gas butterfly valve until flame develops. Refer to specific BMS manual for instructions on how to accomplish this setting change.

• It is normal for flame to appear orange during ignition and low fire setting.

• Check ALL remaining gas connections for gas leaks.

• Allow the heat exchanger and the dry oven to slowly heat up before increasing firing rate. 12. Please refer to the BMS manual for further commissioning instructions.

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IGNITION TROUBLESHOOTING

A problem with burner ignition is one of the most common problems to occur in a burner system. Typically, these

problems are due to improper adjustment or maintenance. This list is intended to cover the most common ignition

problems which occur and potential actions to take. This list is not exclusive, but should be used as a starting point

when problems are occurring with the ignition.

Problem Possible Cause Action

Motor runs but ignition spark does not occur.

Ignition cable or electrode loose or grounded.

Check to insure ignition cable is securely plugged into the electrode. Check cable or replace if necessary.

Remove and check electrode insulator for cracks.

Using a multimeter set to resistance (Ohms or Ω), check resistance between the ignition electrode and the ground. The resistance should show as infinite (overload). If resistance is less than infinite the ignition electrode is grounded. Check entire ignition electrode for potential grounding locations. Check the gap (distance X) between the electrode and the gas nozzle.

Pilot ignition transformer defective.

Check for primary voltage on ignition panel terminal. Replace transformer if needed.

Defective flame safeguard.

Check for primary voltage on ignition panel terminal. Replace flame safeguard if needed.

Motor runs, ignition spark occurs, but gas does not ignite.

No gas supplied to pilot.

Check the main and the manual pilot gas shutoff valve to ensure it is open.

Make sure gas line has been purged of air or other gaess.

Ensure the pilot orifice and supply line are free of obstruction. If they are obstructed, clean.

Check inlet gas pressure and adjust gas pilot regulator if required.

Pilot gas valve does not open.

Check for primary voltage to pilot/gas valve. Check valve action by sound and feel.

Improper gas flow to pilot. Increase or decrease gas pressure to pilot.

Motor runs, gas pilot lights, but pilot flame does not prove and control locks out of pilot

flame failure.

Improper gas flow to pilot. Increase or decrease gas pressure to pilot.

Flame sensor dirty. Clean or replace sensor.

Flame sensor cannot see pilot.

Look through sight tube. If unable to get clear view of pilot, adjust sight tube.

Improper ground circuit.

Check for voltage on neutral wire to panel ground. Voltage should not be more than 0.5 Volts.

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ACCESS COMBUSTION...2. Slowly open incoming gas valve (2) and measure incoming gas pressure. a. Close the incoming gas valve if main gas pressure exceeds maximum pressure ratings on