D/LND SERIES - Industrial Combustion

1 D/LND SERIESI nstallation, Operation, and Service Manual!DANGERWARNINGONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST, OR SER-VICE THIS EQUIPMENTIC-79010/10D/LND SERIESI nstallation, Operation, and Service ManualManual Number: IC-790 Release Date: October 2010 Copyright 2010 by Industrial CombustionAll rights reserved. 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 Combustion351 21st StreetMonroe, WI and caution references have been made in this manual and should be adhered to for smooth operation of the designations are based on the type of fuel(s) to be fired and the amount of furnace pressure to be overcome. Burner size is based on firing rate (rated input in Btu/hr).

2 S-Models for up to furnace for up to furnace : The model number on the nameplate is DLG-252, No. 2 oil and gas burner with input rated at 25,200 MBtu per hour, against furnace pressures up to 4 at installation of a burner shall be in accordance with the regulations of authorities having jurisdic-tion. The equipment must be installed in accordance with applicable local, state, or provincial instal-lation requirements including the National Electrical Code (NEC) and Associated Insurance Underwriters. Where applicable, the Canadian Gas Association (CGA) B149 and Canadian Standard Association (CSA) B140 and B139 (for oil burners) codes shall prevail. OIl and gas burning equip- This symbol precedes information which, if disregarded, may result in injury to the user of the burner or to others. This symbol precedes information which, if disregarded, may result in damage to the burner.

3 NOTE: This symbol precedes information which is vital to the operation or maintenance of the StandardsFuel-Air AtomizationDGGasDL#2 OilDLG#2 Oil and GasDM#2-5 OilDMG#2-5 Oil and GasDE#2-6 OilDEG#2-6 Oil and Gas NOTE: Firing at higher furnace pressures de-rates the burner by approximately 5% per one half inch of additional pressure. Consult with the factory.!Warning!Cautionment shall be connected to flues having sufficient draft at all times to assure safe and proper opera-tion of the D SERIES burners are designed to burn either gas or light oil No. 1 or 2 as defined by ASTM D396-1978 specifications, and heavy oils. Do not use gasoline, crankcase oil, or any oil containing input based on natural gass at 1,000 Btu/cu. ft. and specific SizeMax. Burner Gas Input (S or P)4,2003,36054 (S or P)5,4004,20063 (S or P)6,3005,25084 (S or P)8,4006,300105 (S or P)10,5008,400145 (S or P)14,50010,500175 (S or P)17,50014,700210 (S or P)21,00016,800252 (S or P)25,20021,000300 (S or P)30,00025,200315 (P)31,50030,000336 (P)33,60031,500378 (P)37,80033,600420 (P)42,00037,800 Oil input based on No.

4 2 oil at 140,000 SizeMax. Burner Oil Input (S or P)302454 (S or P)393063 (S or P)473884 (S or P)6053105 (S or P)7560145 (S or P)10790175 (S or P)125105210 (S or P)150120252 (S or P)180150300 (S or P)215180315 (P)225215336 (P)240225378 (P)270240420 (P)300270IC-790 (revised 2010) D/LND SERIES ManualiD/LND SeriesTable of ContentsCHAPTER 1 Introduction Operating Flame Safeguard Combustion Air Handling Firing Rate Firing Oil System Air 3-Way Solenoid Valve Nozzle Assembly Burner Mounted Trim Heater Oil Strainer Atomizing Air Proving Switch Air/Lube Oil Tank Integral Air/Oil Unit Air Compressor Oil Metering Separate Compressor Module Gas Main Gas Train Components Pilot Gas Train Components Operation 1-12 CHAPTER 2 Introduction Application2-1iiIC-790 (revised 2010)

5 D/LND SERIES Combustion Chamber Packing Plastic Refractory Around Separate Compressor Typical Oil Supply Oil Circulating Loop Circulating Oil Oil Loop Burner Mounted Trim Back Pressure Gas Installation Checklist2-9 CHAPTER 3 Operation Preparations for Oil Flow Oil Pressure Oil Temperature Air-Oil Tank (Lube Oil) Firing Preparations for Gas Burners Electrical Interference Gas Fired Oil Fired Gas Pilot Flame Adjustment3-4IC-790 (revised 2010) D/LND SERIES Startup Automatic Manual Safety Startup and Gas Burners Oil Burners Normal Shutdown3-7 CHAPTER 4 Adjustments Combustion Adjustment on Gas and Stack Temperature Smoke Measurement Gas Adjustments Fuel Oil Adjustments Electrical Interference Gas Fired Oil Fired Gas Gas Pressure Gas Flow Gas Pilot Flame Adjustment Main Gas Pressure Regulator Low Gas Pressure Switch High Gas Pressure Switch Gas Combustion Adjustment Secondary Valve Adjustment: Gas Models D 378 & 420 Secondary Valve Adjustment.

6 Dual Manifold 4-5ivIC-790 (revised 2010) D/LND SERIES Oil Oil Metering System Atomizing Air Pressure Atomizing Air Proving Switch Low Oil Pressure Switch High Oil Temperature Switch Nozzle Line Heater Linkage: Modulating Cam Trim Firing Rate Air-Oil Tank Oil Level Sight Gauge Compressor Oil Filter (Lube Oil Strainer) Oil Strainers 5-7 CHAPTER 5 Maintenance Control Programming Control Impeller and Stator Firing Head Pilot and Ignition Flame Oil Firing Rate Burner Mounting Inspection5-6IC-790 (revised 2010) D/LND SERIES Fuel Oil Fuel Oil Circulating Pump Air-Oil Metering Pump Primary Air Pump or Compressor Air Cleaner Air-Oil Tank Oil Level Sight Gauge Compressor Oil Filter (Lube Oil Strainer)

7 Nozzle Line Heater Oil Strainers Gas Motorized Main Gas Valves Solenoid Valves Electrical Electric Motors Extended Maintenance Flow Chart Recommended Test Schedule5-11 CHAPTER 6 Troubleshooting Emergency Troubleshooting6-3 CHAPTER 7 Accessories Steam Atomizing Air Purge System (optional) Plant Air System7-2viIC-790 (revised 2010) D/LND SERIES ManualCHAPTER 8 Flue Gas Recirculation LN Model Designations, Sizes, and FGR Shutoff FGR Control Air/FGR Damper Blast Tube Temperature Interlock (optional) Stack Temperature Interlock (optional) 20 PPM Design8-7 CHAPTER 9 Parts Lists and Drawings Parts Shipping Return Goods Procedures (Credit or Replacement Parts) Parts Lists and Blast Tube Assembly D42 - 336 Blast Tube Assembly D378 - 420 Blower Housing Assembly D42 - 175 Blower Housing Assembly D210 - 336 Blower Housing Assembly D378 - 420 Compressor Set D42 - 145 Compressor Set D175 - 336 Compressor Set D378 - 420 Control Package, Fireye Control Package, Honeywell Damper Assembly D42 - 420 Damper Assembly LND42 - 420 Drawer Assembly D42 - 63 Drawer Assembly D84 - 145 Drawer Assembly D175 - 336 9-32IC-790 (revised 2010)

8 D/LND SERIES Drawer Assembly D378 - 420 Firing Head Assembly D42 - 420 Oil Air Tank DL, DM42 - 145 Oil Heater D42 -420 Oil Metering Assembly DL, DLG, DM, DMG42 - 145 Oil Metering Assembly DL, DLG, DM, DMG175-420 & DE, DEG42 - 420 Oil Metering Assembly D378 - 420 Modulation, Standard Modulation, Standard Low NOx or Left Hand Gas Modulation, Cam Trim Modulation, Cam Trim Low NOx or Left Hand Gas 9-52 STARTUP/SERVICE REPORTWARRANTY POLICY viiiIC-790 (revised 2010) D/LND SERIES ManualIC-790 (revised 2010) D/LND SERIES Manual1-1 CHAPTER OverviewIndustrial Combustion D/ SERIES burners are assembled, wired, and tested at the factory. They are listed by the Underwriters Laboratory, CSD-1, NFPA-85, , , including the National electrical Code (NEC) and associ-ated insurance underwriters.

9 Where applicable, the Canadian Gas Association (CGA) B149 and Canadian Stan-dards Association (CSA) B140 codes shall prevail. Other regulatory agency control options are available. The operator must be familiar with the individual functioning of all controls to understand the operations and procedures described in the manual. Identify and locate each item in the illustrations as they are described in the following DescriptionThe Industrial Combustion D/ SERIES oil burners are of the low pressure, air atomizing (nozzle) type. Gas burners are of the peripheral mix type. All burners feature ignition by spark-ignited gas pilot flame. With either fuel, the burner operates with full modulation. A switch permits changeover from automatic fully modulated firing to man-ually set firing at any desired rate between minimum and maximum.

10 Additional safeguards assure that the burner always returns to minimum firing position for ignition. D/ SERIES burners are designed for automatic, unattended operation except for periodic inspection and mainte-nance. After selecting the proper overload settings for the starter, the rest of the control panel components require little attention except for occasional factory authorized burner service personnel should start-up, adjust, or service this equipment.!CautionIntroduction1-2IC-790 (revised 2010) D/LND SERIES Operating ControlsThe control panel contains a flame safeguard programming control, motor starters, relays, time delays, and ter-minal strips mounted internally on a panel subbase. Lights, switches, potentiometers, a control circuit breaker, and flame safeguard displays are mounted externally on the panel as Flame Safeguard ControlsThe flame safeguard programmer incorporates a flame sensing cell (scanner) to shut down the burner in the event of pilot flame or main flame failure.