Limpsfield LC Series Operating instructions

O&M Manual
LC burner series
Limpsfield Combustion Engineering Limited.
Unit 10 Airport industrial estate
Wireless Way
Biggin Hill
Kent
United Kingdom
T 16 3BW
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Web: www.limpsfield.co.uk

Limpsfield Combustion Operating and Maintenance
Manual
Contents
Section
Contents
Sec
tion
Legal statements and Disclaimers 1
Burner Technical data 2
Component Information 3
Gas manifold
4
Oil gun assembly 5
Electrode settings 6
Burner installation 7
Typical UL Gas control Train 8
Typical Oil Train 9
General start up procedure for all fuels
10
Service recommendations
11
General burner servicing procedure 12
Fault finding 13
Commissioning Report 14

Section 1
Legal statements and Disclaimers
Burner assembly area

Legal Notice
Operation instruction for Limpsfield Combustion Equipment to guarantee safety, reliability
and efficiency.
The end user should carry out only operational adjustments & routine maintenance. Operational
adjustments would include adjusting temperature or pressure settings on the burner management
system. Maintenance by the end user should be limited to checking peripheral equipment such as
fuel filters, fuel flow meters and fuel supply pressures. Any malfunction of the control system or
burner must be attended to by a qualified technician who has been trained by the manufacturer of
the equipment or his accredited representative. Commissioning, fault finding or any system
equipment modification must absolutely only be implemented by manufacturer trained and approved
technicians/engineers.
Various training schemes can be arranged at or our works or on site with suitably qualified
personnel by prior arrangement with our service support department.
All personnel working on boilers/combustion system should hold suitable qualifications in an
appropriate discipline. All personnel should have received training from the relevant manufacturer.
All personnel should have or be supplied with appropriate clothing i.e. boiler suit, hard hat, safety
glasses and suitably robust foot ware. Any technician/operative must ensure he has access to the
appropriate technical documentation, the correct tools and test equipment to safety and efficiently
deal with the scope of work set out in the job instruction.
If the end user and installer follow the recommendations and instructions set out above the safe,
reliable and efficient operation of the combustion system will be guaranteed and many years of
trouble free operation will be assured.

Important Notice to the end user and operator.
To ensure:
1. Safety
2. Efficiency
3. Reliability
of the system. It is vital that all of the component parts in a combustion system installation are
serviced and inspected for soundness/correct operation at 12 monthly intervals. The particular
installation and the way in which it is used may require more frequent servicing and inspections.
Always contact the manufacturer for advice if in any doubt of your particular requirements.
It is, therefore, vitally important that any of the following works:
1. Servicing
2. Inspections
3. Remedial Breakdown Works
4. System Modification and Enhancements
be carried out by qualified and experienced technicians who have received training from the
manufacturer. If in any doubt as to the technical proficiency of any person or organisation offering
field service and support, always contact the manufacturer for their recommendations.
Always remember:
Expert Servicing = Safety, Efficiency and Reliability

Hints and General Advice to the End-User/Operator
Please be aware that many components and systems in a modern installation are ‘service free’ or
‘lubricated and sealed for life’. This means that although no servicing is required it is still of the
highest importance that these items of equipment are inspected regularly to ensure that they are
sound and still meeting their originally specified performance. Components in a system can become
degraded or damaged by the installation being operated in an inappropriate manner. Regular
inspection by an experienced technician will identify any of these situations before they become
troublesome.
‘The more care taken with the system and component maintenance the greater the reliability and
reduced down-time’
Inspection must be made on a regular basis of the following systems/components:
1. Electrical Control Panels
2. Electronic Control Modules
3. Boiler Flue Side Heat Transfer Surfaces
4. Fuel Pumping and Filtering Systems
5. Flue Dampers and Flue Gas Recirculation (FGR) Systems
6. Air Filters, Fans and Silencers
7. Gas Pressure Control Rigs
8. Flues and Exhaust Ducts
9. Level Controls and Blowdown Systems
10.Refractory Insulation
11.Burner Ignition and Flame Safeguard Systems
Any abnormal occurrence or condition on the system must be investigated by a trained and
technically competent person who has been trained by the manufacturer of the relevant equipment.
A malfunction or abnormal condition would include, Flame Failure, Lockout, High Limit
Temperature/Pressure, Low Gas Pressure, Low Oil Pressure, e.t.c. Any abnormal condition will be
indicated by warning lights or alphanumeric electronics displays, e.t.c. In the interest of safety and
reliability a clear reason must be established for any abnormal condition, system malfunction or
failure before the system can be put back into normal operation. The reason for malfunction and the
recovery procedure must be made and logged by a well trained and technically proficient engineer,
who has received training by the relevant manufacturer.
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR
SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL
INJURY AND PROPERTY DAMAGE.

Section 2
Burner Technical Data
Gas flame firing at 12,300,000 btu/hr

Burner Data
Note: Volume of air and flue gases is calculated based around the following criteria. Exhaust gases
at 230°C/446°F ambient air at 20°C/68°F, mix of flue gases and air at 62.9°C/145.22°F with O2at
18.5% dry volume in the wind box.
Burner Type Number 9 15 21 36 44 53 62 73
Burner Rating Mw 0.9 1.5 2.1 3.6 4.4 5.3 6.2 7.3
Mmbtu 3 5 7 12.3 15 18 21 25
Air at 15% Excess Cuft/hr 33,465 55,775 78,085 137,206 167,325 200,790 234,255 278,875
Air + FGR @62.9°C/145.22°F
Cuft/hr 41,831 69,718 97,606 171,507 209,156 250,987 292,818 348,593
No.2 Oil input rate
(137,080 btu/gal) GPH 21.88 36.47 51.06 89.72 109.43 131.31 153.19 183.38
Gas input rate (1000 btu/cuft)
Cuft/hr 3000 5,000 7,000 12,300 15,000 18,000 21,000 25,000
Minimum Pilot pressure “WG 12 12 12 12 12 12 12 12
Delta P Air "WC 7 10 11 12 12 12 12 12
mbar 17.4 24.9 27.4 29.88 29.88 29.88 29.88 29.88
Delta P Air + FGR "WC N/A N/A 16.5 18 18 18 18 18
mbar N/A N/A 41 44.8 44.8 44.8 44.8 44.8
Blast tube O.D. MM 176 189 202 299 314 361 386 417
Inches 6.92 7.44 7.95 11.77 12.36 14.21 15.19 16.41
Gas inlet (NPT or 150lb) 2" npt 2" npt
2.5"
150lb
2.5"
150lb
2.5"
150lb
3"
150lb 3" 150lb 4" 150lb
Nominal Gas train size 2” – 3” 2” – 3” 2” – 4” 2” – 4” 2” – 4” 3” – 4” 3” – 4” 3” – 5”
Mounting P.C.D. MM 240 240 240 355 355 440 440 570
Inches 9.45 9.45 9.45 13.97 13.97 17.32 17.32 22.44
Mounting hole Ø MM 8.5 8.5 8.5 10.5 10.5 10.5 10.5 17
Inches 0.33 0.33 0.33 0.41 0.41 0.41 0.41 0.67
Quantity of mounting holes 4 4 4 8 8 8 8 8
Burner Type Number 88 100 123 150 175 200 263 310
Burner Rating Mw 8.8 10 12.3 15 17.5 20 26.3 31
Mmbtu 30 35 42 50 60 70 90 110
Air at 15% Excess Cuft/hr 334,650 390,425 468,510 557,750 669,300 780,850 1,003,950 1,227,050
Air +
FGR @62.9°C/145.22°F
Cuft/hr 418,312 488,031 585,637 697,187 836,625 976,062 1,254,937 1,533,812
No.2 Oil input rate
(137,080 btu/gal) GPH 218.85 255.33 306.39 364.75 437.70 510.65 656.55 802.45
Gas input rate (1000 btu/cuft)
Cuft/hr 30,000 35,000 42,000 50,000 60,000 70,000 90,000 110,000
Minimum Pilot pressure “WG 12 12 12 12 12 12 12 12
Delta P Air "WC 12 12 12 12 12 12 12 12
mbar 29.88 29.88 29.88 29.88 29.88 29.88 29.88 29.88
Delta P Air + FGR "WC 18 18 18 18 18 18 18 18
mbar 44.8 44.8 44.8 44.8 44.8 44.8 44.8 44.8
Blast tube O.D. MM 456 490 540 582 638 687 775.5 852
Inches 17.95 19.29 21.25 22.91 25.11 27.04 30.53 33.54
Gas inlet (NPT or 150lb)
4"
150lb
4"
150lb
6"
150lb
6"
150lb
6"
150lb
6"
150lb 8" 150lb 8" 150lb
Nominal gas train size 3” – 5” 3” – 5” 4” – 6” 4” – 6” 4” – 6” 4” – 6” 4” – 6” 4” – 6”
Mounting P.C.D. MM 570 570 785 785 785 785 998.5 998.5
Inches 22.44 22.44 30.9 30.9 30.9 30.9 39.31 39.31
Mounting hole Ø MM 17 17 14 14 14 14 21 21
Inches 0.67 0.67 0.55 0.55 0.55 0.55 0.82 0.82
Quantity of mounting holes 8 8 12 12 12 12 8 8

Section 3
Component Information
General assembled burner

Component Information
8
9
10
5
2
1
4
3
6
7
11
12
13
14
17
16
15
OilR
eturntoT
ank
18
1. Sight Glass Assembly/Access Door
2. Oil Gun Assembly
3. Oil Flow to Lance Hose
4. Oil Return from Lance Hose
5. Gas Manifold
6. Combustion Air Servo Motor
7. Combustion Air Damper
8. Rear Burner Wind box
9. Front Burner Wind box
10. Blast Tube Assembly
11. Terminal Box Assembly/Transformer Mounting Bracket
12. Terminal Box
13. Ignition Transformer
14. Normally Closed Oil Solenoid Valves
15. Fuel Servo Motor
16. Oil Metering Valve
17. Gas Control valve (Lc9-15 screwed type / Lc21-310 flanged type)
18. Gas Nipple (Lc9-15 only)
Note: The above diagram is a general arrangement for illustrational purposes only. Some
burners may differ slightly.

Section 4
Gas Manifold assembly
Split gas head assembly

Gas Manifold
Gas Manifold Removal
4
1
5
3
7
6
2
8
1. Sight GlassFastening Screws
Figure 1: Burner Isometric
2. Sight Glass Assembly
3. GasManifold Assembly
4. 4 ea. GasManifold Fastening Screws
5. GasManifold Mounting Plate
6. Burner Housing
7. Burner Blast Tube
8. GasManifold O-Ring Seal
Figure 2: GasManifold Removal
A unique design feature of the Limpsfield burner is the accessibility to all internal parts without removing the
burner from the boiler. This allows for ease in set-up, maintenance and servicing.
Warning: Ensure all electrical power is removed prior to servicing equipment
Step 1: Remove all sight glass fastening screws (item 1 on the diagrams above) and remove the sight glass
assembly (item 2) from the burner
Step 2: Remove the 4 fixings for the gas manifold from gas manifold mounting plate (item 5). Pull the
electrode wires (not shown) and carefully remove manifold assembly (item 3) from the burner blast tube (item
7) and housing (item 6). Use extreme caution so as not to damage the gas seal o-ring (item 8) and the
ignition electrodes during the removal procedure.
Once adjustments to the gas manifold have been made, replace the gas manifold and sight glass assembly
in the reverse order of the above method.

Adjusting the Orifices Plate Gap Setting (Split Head Design)
Figure 3: GasManifold
1
2
4
56
7
8
3
1. Primary Air Tube
2. GasManifold
4. 3 ea. Jam Screw / Washer
3. 3 ea. Gap Adjusting Screw
8. Adjustible Orifice Plate
7. 3 ea. Diffuser Fastening Screw
6. Diffuser Plate
5. 3 ea. Diffuser Spacer
Figure 4: Pilot Injector
Diffuser Face
1/ 8" (3mm)
Pilot Injector Disc
Pilot Injector Body
Set Screw
Pilot GasSupply Line
To alter the orifice plate gap setting, the gas manifold (item 2) must first be removed from the burner. To do
this, follow the procedure outlined on the previous page. Once the gas manifold has been removed, the
diffuser (item 6) must be removed. Once removed, the service person has access to the adjustable orifice
plate (item 8).
Step 1: If the burner is equipped with a proven gas pilot (Lc21-310), the pilot injector disc must be removed.
Loosen set screw to allow for removal of the pilot injector disc assembly (figure 4).
Step 2: Remove 3 ea. Diffuser fastening screws (item 7) and diffuser stand off pillars (item5).
Step 3: Loosen 3 ea. Jam screw/washer (item 4) on the orifice plate.
Step 4: To DECREASE the gap setting, rotate the gap adjusting screw (item 3) clockwise as illustrated in
Figure 5 on the next page. To INCREASE the gap, rotate counter-clockwise. Using a measuring scale or gap
gauge, adjust all three screws so that the gap setting is equally maintained around the circumference of the
assembly. The orifice plate is free to slide along the primary air tube (item 1).
(Instructions continue on next page.)

Step 5: Once the desired gap has been obtained, tighten jam screws/washers as illustrated in Figure 6. The
washer, once tight, should compress against the head of the gap adjusting screw (item 3). Ensure that this is
the case. Replace washer as needed if compression does not take place.
Step 6: After jam screws/washers have been installed, re-assemble diffuser and diffuser stand off pillars to
their original position. Install pilot injector disc, setting the gap to its original position (1/8” or 3mm). DO NOT
FORGET TO TIGHTEN SET SCREW, located in the pilot injector body.
IMPORTANT NOTE:
Adjustments in the orifice plate gap setting will change the gas flow rate (hence, gas pressure) from their
original values. DECREASING the gap will allow less gas flow per the same pressure. Likewise,
INCREASING the gap will allow more gas flow per the same pressure. Thus, the burner fuel/air ratio may
change and require alterations to be made from the original commissioned values. Refer to the Autoflame
Technical Manual and the “Single Point Change Facility” for assistance. If in doubt, a re-commission should
be carried out.
Only trained service personnel should make adjustments in the orifice plate gap setting. Call your local
service company for assistance in making any adjustments to any piece of combustion equipment.
Figure 5: Gas Adjustment
Figure 6: Jam Screw/Washer
"T
"HandleAllenWrench
GapS
etting
3
4
Gap Adjusting Screw
JamScrew/ Washer

Adjusting the Orifices injector Setting (Spider Head Design)
Spider heads are factory set for an inlet pressure of 5 psi to produce the required injection to enable
correct fuel to air ratio. These settings can be adjusted to suit on site conditions. Below is the
recommended procedure to adjust the gas injectors. It is important that the injectors are set to the
same gap setting.
Setting the injectors is ideally achieved using a feeler gauge like used to set the gaps on spark plugs in an
internal combustion engine. This should be carried out as follows:-
•Remove the gas head assembly from burner.
•Feeler gauges should first be selected for the correct injector setting. In this case 1mm.
•The injector should be loosened off and the feeler gauge inserted between the injector and pipe.
•The injector should then be pushed up against the feeler gauge, and locked in position. It is important
that care is taken to ensure that the injector is securely locked in position by the gas injector locking
screw.
•The feeler gauge should then be slid out from between the injector and pipe.
•Gas head is now ready to re-install.
1mm
Gas injector
Diffuser
Gas injector
locking screw

Section 5
Oil Gun assembly
Oil nozzle and lance assembly

Oil Gun Assembly
KC2 Oil Gun (LC 9/15)
The LC9 and 15 burner models operate on a bypass pressure atomization system. The KC2 series bypass
nozzle requires approximately 300 psi (20 bar) of oil supply to the nozzle.
Bypass pressures at high and low fire (for a 4:1 turndown) are approximately 220 psi (16 bar) and 60 psi (4
bar) respectively.
OilGunR
etainingS
crews
NozzleF
lowP
ipe
OilL
anceS
upportCollar
KC2OilNozzleCarrier
KC2B
ypas
s
Nozzle
NozzleR
eturnP
ipe

W2 Oil Gun (LC 21-310)
Burner models from LC 21 upward operate on a high-pressure atomization system. The W2 series bypass
nozzle requires approximately 368 psi (25 bar) of oil supply at the nozzle. Bypass pressures at high and low
fire (for a 4:1 turndown) are approximately 310 psi (21 bar) and 160 psi (11 bar) respectively. The W2 nozzle
incorporates a positive mechanical “Nozzle Shutoff” system that ensures no after drip after burner shutdown.
This feature requires approximately 75 psi (5 bar) of oil pressure at the nozzle to open. Upon initial
commissioning of oil, the commissioning engineer may have to close the spillback/metering valve an
incremental amount if ignition does not take place. The opening pressure can be measured with a 0-600 psi
(0-40 bar) oil pressure gauge via the pressure port in the spillback/metering valve.
Figure 3: W2 Oil Gun with Proven GasPilot
W2OilNozzleCarrier
Figure 2: Typical Oil Gun Installation
R
F
NozzleF
lowP
ipe
OilGunR
etainingS
crews
W2OilNozzlewithS
hutoff
NozzleR
eturnP
ipe
R
F

Section 6
Electrode settings
Pilot injector and ignition setup

Electrodes
Staged Ignition (LC 9/15)
STANDARD ELECTRODEHOLDER
STOCK ELECTRODE
(manufactured by westwood)
Diffuser
Figure 1: General Layout Electrodes Lc9/15
DIFFUSSER
3mmGAP
ELECTRODE
TO BESPACED OF
BY20mmPILARS
3mmOR1/ 8"
Figure 2: Staged Ignition Electrodes Lc9/15
Staged ignition Electrode Setting:
Limpsfield LC9 and 15 burners utilize a “staged” pilot gas ignition system. The pilot gas is introduced into the
main gas manifold, prior to the gas-metering valve. At the proper sequence, the ignition transformer
energizes and a spark is generated at the electrode tips located directly above the orifice plate gap. At this
time the pilot gas is ignited and may burn behind the diffuser. Once the main gas valves energize, main
ignition takes place and the gas should move from behind the diffuser and retain to the diffuser face. The
figure above illustrates proper ignition electrode gap setting. Distance between electrodes should be kept to
approximately 1/8” or 3mm. The electrodes should be positioned approximately 3/16” or 5mm above the
orifice plate.