Installation Operation, Service, and Parts Manual

1 M/SERIESI nstallation, Operation, Service, and Parts Manual !DANGERWARNINGONLY FACTORY AUTHORIZED BURNER SERVICE PERSONNEL SHOULD START UP, ADJUST, OR SER- vice THIS EQUIPMENTIC-99309/10 M SERIESI nstallation, Operation, Service, and Parts ManualManual Number: IC-993 Release Date: September 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 Industrail Combustion351 21st StreetMonroe, WI and caution references have been made in this Manual and should be adhered to for smooth opera-tion of the designations are based on the type of fuel(s) to be fired and the amount of furnace pressure to be over-come. Burner size is based on firing rate (rated input in Btu/hr).The Installation of a burner shall be in accordance with the regulations of authorities having jurisdiction.

2 The equipment must be installed in accordance with applicable local, state, or provincial Installation 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 burn-ers) codes shall prevail. OIl and gas burning equipment shall be connected to flues having sufficient draft at all times to assure safe and proper operation of the M/Series burners are designed to burn either gas or light oil No. 1 or 2 as defined by ASTM D396-1978 specifications, and heavy not use gasoline, crankcase oil, or any oil containing : The model number on the nameplate is MM-42, indicating it is a combination No. 2 to 5 oil burner with input rated at 4,200 MBtu per hour, against furnace pressure to This symbol precedes information which, if disregarded, may result in injury to the user of the burner or to oth-ers.

3 This symbol precedes information which, if disregarded, may result in damage to the burner. NOTE: This symbol precedes information which is vital to the operation or maintenance of the ModelsFuel (Air Atomization)MGGasMLG#2 Oil and GasMM#2-5 OilMMG#2-5 Oil and GasME#2-6 OilMEG#2-6 Oil and Gas!Warning!CautionBurner size and rated furnace pressure - M/Burner:M14 to 30 to 105 to burner nameplate data for correct manifold input based on natural gas at 1,000 Btu/cu. ft. and pressure based on zero furnace pressure. For total pressure at manifold, add furnace input based on oil at 150,000 overall efficiency of 80% HP is based on altitude up to 2,000 ft. above sea level. For higher altitude or 50 Hz. applications, consult motor voltages are 208-230-460/3 SELECTIONS:1 - Use model S up to furnace - Use model P up to furnace higher furnace pressures, consult M Series SpecificationsBurner ModelFrame SizeGas Input (MBH)Oil Input (GPH)BHP @ 80% Motor HP S 2 Motor HP P Separate Comp.

4 Module Motor HP Oil Metering System Motor HPNozzle Line Heater 3PH (KW)Std. Gas Train Size (In.)Gas Pressure Required ( )MEG-1411,400 ,680 ,960 ,200 ,490 ,800 ,150 ,500 ,200 ,600 ,300 ,400 ,500 input based on natural gas at 1,000 Btu/cu. ft. and pressure based on zero furnace pressure. For total pressure at manifold, add furnace input based on No. 2 oil at 140,000 overall efficiency of 80% HP is based on altitude up to 2,000 ft. above sea level. For higher altitude or 50 Hz. applications, consult motor voltages are 208-230-460/3 SELECTIONS:1 - Use model S up to furnace - Use model P up to furnace higher furnace pressures, consult M Series SpecificationsBurner ModelFrame SizeGas Input (MBH)Oil Input (GPH)BHP @ 80% Motor HP S 2 Motor HP P Integral Oil/Air System Motor HPStd.

5 Gas Train Size (In.)Gas Pressure Required ( )MLG-1411,400 ,680 ,960 ,200 ,490 ,800 ,150 ,500 ,200 ,600 ,300 ,400 ,500 input based on natural gas at 1,000 Btu/cu. ft. and pressure based on zero furnace pressure. For total pressure at manifold, add furnace input based on No. 4 - 5 oil at 145,000 overall efficiency of 80% HP is based on altitude up to 2,000 ft. above sea level. For higher altitude or 50 Hz. applications, consult motor voltages are 208-230-460/3 SELECTIONS:1 - Use model S up to furnace - Use model P up to furnace higher furnace pressures, consult M Series SpecificationsBurner ModelFrame SizeGas Input (MBH)Oil Input (GPH)BHP @ 80% Motor HP S 2 Motor HP P Integral Oil/Air System Motor HPNozzle Line Heater 3PH (KW)Std. Gas Train Size (In.)Gas Pressure Required ( )MMG-1411,400 ,680 ,960 ,200 ,490 ,800 ,150 ,500 ,200 ,600 ,300 ,400 ,500 (revised 2010)

6 M/Series ManualiM/SeriesTa b l e o f C o n t e n t sCHAPTER 1 Introduction Operating Control Panel Flame Safeguard Controls Flame Scanner Motors Motor Starters Ignition Transformer Modulating Motor Combustion Air Operation Gas Pilot Gas Operation Oil Air Atomizing Burners 3-Way Solenoid Valve Nozzle Assembly Nozzle Line Electric Heater Oil Strainer Atomizing Air Proving Switch Air/Lube Oil Tank Integral Air/Oil Unit Air Compressor Oil Metering Separate Compressor Module Burners Air Compressor Module Oil Metering Operation 1-10iiIC-993 (revised 2010)M/Series ManualCHAPTER 2 Installation Draft Combustion Air Combustion Chamber Dry Oven and Burner Compressor Gas Fuel Oil Air Atomizing Systems Circulating Oil Pump Oil Loop Heaters Installation Checklist2-9 CHAPTER 3 Operation Preparation for Initial Firing Preparations for Gas Firing Preparations for Oil Oil Flow Oil Pressure Oil Temperature Sequence of Startup and Gas Burners Oil Burners Normal Shutdown3-6IC-993 (revised 2010)

7 M/Series Extended Shutdown3-6 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 (28-105) High Gas Pressure Switch (28-105) Gas Combustion Adjustment Oil Oil Metering Unit Atomizing Air Pressure Atomizing Air Proving Switch Nozzle Line Heater Combustion Air Modulating Linkage Cam Trim (Fine Tuning the Modulating Cam) 4-8 CHAPTER 5 Maintenance Introduction5-1ivIC-993 (revised 2010)M/Series Control Programming Control Combustion Air Impeller Gas Motorized Main Gas Valves Solenoid Valves Oil Oil Metering Unit Nozzle Line Heater Air Compressor Lubricating Oil Air-Oil Tank Oil Level Sight Gauge Compressor Inlet Oil Strainer (Lube Oil Strainer) Air Cleaner Lube Oil Cooling Coil Motor Sheave Alignment and Belt Tightening Burner Pilot, Ignition Electrode and Ignition Cable Air Atomizing Nozzles Flame Scanner Diffuser Burner Mounting Oil Drawer Maintenance Flow Chart5-12 CHAPTER 6 Troubleshooting Emergency Troubleshooting6-3IC-993 (revised 2010)

8 M/Series ManualvCHAPTER 7 Ordering and Parts Lists Ordering Parts Shipping Policy Return Goods Procedures (Credit or Replacement Parts ) Motor Warranty Policy Marathon Electric Motors Warranty Repair Procedure* Parts Lists and Blower Housing & Blast Tube Assemblies Drawer Assembly, M 14-63 Drawer Assembly, M 84-105 Oil Piping Assembly, Pressure Atomizing - ML Air Atomizing Oil Metering Assembly MM, ME Oil Piping Assembly, Air Atomizing, ME 34-105 Separate Compressor Module, ME 34-54 Separate Compressor Module, ME 63-105 Main & Pilot Gas Trains Air & Electric Modulation, Linkage Electric Modulation with Cam Trim: MM, MMG, ME, MEG 34-105 Panel Box and Control System Standard Components 7-32 WARRANTYSTARTUP REPORTPRODUCT SATISFACTION SURVEYviIC-993 (revised 2010)M/Series ManualIC-993 (revised 2010)M/Series Manual1-1 CHAPTER OverviewIndustrial Combustion M/Series burners are assembled, wired, and tested at the factory.

9 They are listed by the Underwriters Laboratory, CSD-1, NFPA-85, , , and other regulatory agency control options are operator of this equipment must be familiar with the individual functioning of all controls to understand the operations and procedures described in this Manual , and supplementary instructions provided with optional con-trols. DescriptionThe industrial Combustion M/Series burners are of the low pressure, air atomizing (nozzle) type. All burners fea-ture 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 manually set firing at any desired rate between min-imum and maximum. Additional safeguards assure that the burner always returns to minimum firing position for burners are designed for automatic, unattended operation except for periodic inspection and mainte-nance.

10 After selecting the proper overload settings for the starter, the rest of the control panel components require little attention except for occasional cleaning. Operating ControlsThe burner is supplied with a remote control panel and with a burner mounted junction factory authorized burner service personnel should start-up, adjust, or service this equipment.!CautionIntroduction1-2IC-993 (revised 2010)M/Series Control PanelThe control panel contains a flame safeguard programming control, motor starters, relays, time delays, and ter-minal strips mounted internally on a panel sub-base. Lights, switches, potentiometers, a control circuit breaker, and flame safeguard displays are mounted externally on the panel. The burner control circuit operates on 115 volt, single phase, 60 hertz (or 50 hertz when required) alternating current. The major components Flame Safeguard ControlsAutomatically programs each starting, operating, and shutdown cycle in conjunction with operating, limit, and interlock devices.