Power Flame C1-GO-10 User manual

C MANUAL
POWER FLAME INCORPORATED

COMPONENT INFORMATION-GENERAL
The contents of this manual are general in nature,
due to the wide variety of equipment specifications, in-
surance requirements and state, local and other codes.
1. Blower Motor
2. Blast Tube
3. Air Inlet Housing
4. Air Inlet Damper Manual Adjustment
Arms
5. Air Flow Switch
6. Drawer Assembly Cover Plate
7. Drawer Assembly Adjustment
8. Air Diffuser
9. Flame Retention Ring
10. Gas Pilot Regulator
11. Gas Pilot Solenoid Valve
12. Gas Pilot Test Tee
13. Gas Pilot Assembly
14. Gas Pilot Ignition Transformer
15. Flame Scanner (Detector)
16. Orifice Tee with Gauge Test Port
17. Automatic Gas Valve
18. Leakage Test Cock
19. Oil Pump
20. Oil Solenoid Valve
21. Control Panel
22. On-Off Switch
23. Fuel Selector Switch
24. Hinged (Total Access) Top Section
25. Light and Switch Circuit Board
26. Removable Total Access Door
27. Optional Board for Sequence Indicator Lights
The computer generated Burner Specification Sheets
shipped with the burner represent the as built version
of your specific Power Flame combustion system. Part
numbers and component descriptions will match those
components supplied. A duplicate set of Burner
Specification Sheets is available through Power Flame’s
Customer Service Department.
Figure 1
Burner Component Identification
Typical for Model CR-GO with On-Off Fuel/Air Control Modes of Operation.*
*The components and arrangements shown
are typical for a Model CR-GO combination
gas/oil burner. Gas only or oil only units will
have similar components relating to their
specific fuel. In some cases, the type of
components and/or their arrangement may
vary from this depiction. For specifics on
your system, refer to the technical informa-
tion supplied with the burner.
C3
Rev.703
24
27
26
21
11
10
2
1
2
13
8
76
16
1817
26
21 24 19 34
5
15
12
114
22
23
9
20
25

OIL SUPPLY PIPING
The C burner is designed for use with light grade fuel oils
- commercial standard grades #2 or #1.
It is recommended that prior to installation all national,
local and other applicable codes be reviewed to ensure
total compliance.
It is recommended that prior to installation, NFPA-31
and all other national, state, local and other applicable
codes be reviewed to ensure total compliance with their
requirements including, but not necessarily limited to, the
use of anti-syphon valve(s), oil safety valve(s) (OSV), or
other acceptable means to prevent siphoning of the oil
when tank is above burner level. Even if such devices are
not required by code, they should be considered good
installation practice and mandatory when the tank is
above burner level.
Do not install manual valves in the return line between
the pump and the tank unless required by a specific
code. If a manual valve is required, an automatic relief
valve must be installed across the manual valve to
ensure that oil will bypass directly back to the tank in the
event the manual valve is inadvertently left in the closed
position.
Use copper tubing with flare fittings or iron pipe on all
installations. All units must utilize the proper size and
type of suction line oil filters. See this page, Table 6 for
recommended Power Flame oil filters.
If the oil storage system has been used with fuel heavier
than #2 fuel oil, the entire system should be thoroughly
cleaned and flushed before starting up the new system.
Utilize fusible link and/or overhead anti-siphon valves as
appropriate.
If iron pipe oil lines are used on underground tanks, swing
joints utilizing nipples and elbows must be used and
joined together, making certain the piping connections
are tightened as the tank settles. Keep swing joints in the
suction and return lines as close to the tank as possible.
Underground tanks should be pitched away from the
suction line end of the tank to prevent sediment from
accumulating at the suction line entrance. The suction line
should be a minimum of 3” from the tank bottom.
Before starting up the system, all appropriate air and oil
leak tests should be performed. Make certain that the tank
atmospheric vent line is unobstructed.
Refer to page 12, Figure 11 for fuel pump oil piping
connection information. Further information relating
to burner oil piping can be found in Table 6 this page,
Figure 11 on page 12, and on page 13, Figure 12.
It is very important to properly size the oil suction line and
oil filter, to provide fuel flow to the burner without exceeding
10” suction pressure (vacuum) at the oil pump suction
port.
Table 6
Oil Pump Suction Capacity and Filter Selection Chart
Gas/Oil Model Oil Model GPH Power Flame Alternate
Suction Capacity Oil Filter Model Oil Filter
C1-GO-10 70(1) 73410 (Fulflo FB-6)
C1-GO-12 C1-O and C1-OS 70(1) 73410 (Fulflo FB-6)
C2-GO-15 C2-OA and C2-OAS 70(2) 73410 (Fulflo FB-6)
C2-GO-20A C2-OB and C2-OBS 40 70101-100 73410 (Fulflo FB-6)
C2-GO-20B C2-OB and C2-OBS 40 70101-100 73410 (Fulflo FB-6)
C3-GO-20 C3-O 105 70101-100 73410 (Fulflo FB-10)
C3-GO-25 C3-O 105 70101-100 73420 (Fulflo FB-10)
C3-GO-25B C3-O(B) 135 70101-100 73420 (Fulflo FB-10)
C4-GO-25 C4-OA 135 70101-100 73420 (Fulflo FB-10)
C4-GO-30 C4-OB 135 70101-100 73420 (Fulflo FB-10)
C5-GO-30(B) C5-O(B) 250 70101-100 73290 (#72 1” Hayward
C6-GO-30 C6-O 250 70101-100 with 100 mesh basket)
C7-GO-30(B) C7-O(B) 265 70101-100 73290 (#72 1” Hayward
C8-GO-30 C8-O 265 70101-100 with 100 mesh basket)
1. The standard pump normally supplied is 19 GPH for On-Off
or Modulating and 40 GPH for fixed air low fire start,
Low-High-Off and Low-High-Low operation. Optional
pumps are available which, depending on model specified,
could be as high as 70 GPH. Refer to information shipped
with the burner and/or consult the factory for specifics.
2. The standard pump normally supplied is 40 GPH for Low-
High-Off and Low-High-Low and 70 GPH for On-Off and
Modulating operation. Optional pumps are available for
Low-High-Off and Low-High-Low which could be as high
as 70 GPH. Refer to information shipped with the burner
and/or consult the factory for specifics.
The method to properly size copper tubing is outlined
on page 12 (Figure 10). Consult Power Flame Customer
Services Department for sizing assistance regarding
iron pipe.
73290 (#72 1” Hayward
with 100 mesh basket)
C11
Rev.304

Figure 10
Oil Line Sizing Suction Capacity in G.P.H.
Inches of Vacuum at Fuel Unit
Total Feet of 3/8” O.D.
Copper Tube #2 Fuel Oil
Total Feet of 1/2” O.D.
Copper Tube #2 Fuel Oil
Total Feet of 5/8” O.D.
Copper Tube #2 Fuel Oil
Total Feet of 3/4” O.D.
Copper Tube #2 Fuel Oil
1. Check oil pump GPH Suction Capacity shown in Table 6.
2. Measure total tube length (horizontal and vertical) from the
end of the line in the tank, to the connection at the oil pump.
3. Choose the appropriate graph above based on the tubing
size. Read up from horizontal line Total Feet of Copper Tube
to Suction Capacity in GPH.
4. Read left to the vertical line Inches of Vacuum at Fuel-Unit.
(This is the vacuum required to draw oil through the length
of tubing selected.)
5. If installation has lift (Lift is defined as the vertical distance
the fuel unit is above the top of the tank,) add 1” of vacuum
for every foot of lift.
6. Add the vacuum determined from items 4 and 5 together
to determine total inches of vacuum.
7. If total is over 10”, move to next larger tubing size chart and
re-calculate total inches of vacuum.
8. The instructions above do not allow for any added
restrictions, such as line filter, elbows, sharp bends, check
valves, etc. Suction line vacuum values for such compo-
nents vary by manufacturer.
A Rule of Thumb to determine total vacuum for suction line
sizing is to add 10% to vacuum determined from Figure 10
calculations.
9. It is always safe to size the return line from pump to tank at
the same size as the selected suction line.
DIRECT DRIVE OIL PUMP
DELTA OIL PUMP DETAIL
WEBSTER 3450 RPM BLOWER MOTOR DRIVEN OIL PUMP
SUNTEC TWO STEP PUMP DETAIL
Piping connection
may not be identical
to blower motor
driven pump. See
pump information
supplied with burners.
Pressure Gauge Port 1/8” NPT Vacuum Port 1/8” NPT
Nozzle Port
1/8” NPT
Pressure
Regulator
Inlet Port
1/4” NPT
Inlet Port 1/4” NPT Return Port 1/4” NPT
Vent
Regulator Setting
(with Solenoid De-Energized)
(Low Pressure)
Nozzle Port
1/8” NPT
Pressure
Gauge Port
1/8” NPT
Inlet 1/4” NPT
Inlet 1/4” NPT
Regulator Setting
(with Solenoid Energized)
(High Pressure)
Easy Flow
Air Bleed Valve
Nozzle Port
1/4” NPT
Optional Inlet
1/4” NPT
Optional Inlet
1/4” NPT
1/8” Allen Screw Under
Cover Screw for Nozzle
Pressure Setting
Pressure Gauge Port (or Air Bleed)
Optional Return Port
1/4” NPT
Optional Return Port
1/4” NPT
Figure 11
Oil Pump Details
The oil pumps depicted in this section represent the
most commonly used models. For models not depicted,
such as the Suntec Model J or H, refer to the pump
manufacturer’s bulletin that is supplied with the burner.
C12
Rev.304

MECHANICAL OPERATION: This Low-High-Off system uses a
two-stage Oil Pump (2) with a Simplex Oil Nozzle (see note
1, page 19 & 20) or an internal bypass nozzle in conjunction
with Movable Air Dampers (4) to provide a low fire start and
a high fire run sequence. A direct spark oil ignition system is
standard on typical oil burners (a gas pilot is standard on
Gas/Oil burners) at firing rates up to 45 GPH, with a spark
ignited gas pilot* to ignite the main oil flame above that
point. Certain insurance company codes could require the gas
pilot system on lower input sizes. Nozzle supply pressure is
set by adjusting the Oil Pump Pressure Regulator (3). Turn
clockwise to increase the pressure and counter-clockwise to
decrease the pressure to the Nozzle. Nozzle supply pressure
is taken at the plugged Pump Nozzle Pressure Gauge Port
(6). Nozzle supply pressure will normally be approximately 300
PSI at both high and low firing rates. Flow rate pressure for
both high and low fire is taken at Bypass Pressure Gauge
Tee (15). Low fire pressures are set by adjusting the low fire
Regulating Valve (8). Turning the low fire Regulating Valve
adjustment nut clockwise will increase the pressure at the
Bypass Pressure Test Tee Gauge (increasing the low fire
input) and counter clockwise will reduce the pressure at the
gauge (decreasing the low fire input). Low fire return pressure
will normally be in 60 to 100 PSI range and at high fire in the
180 to 225 PSI range, but both pressures will vary according
to the specific nozzle being used, as well as job conditions.
At light off, the Main Oil Solenoid Valve (1) is energized,
allowing fuel to flow to the Nozzle. At the same instant a
portion of the oil bypasses the Nozzle through the adjustable
low fire regulating valve, reducing the pressure at the Nozzle as
required for low fire rates. When the low fire flame is proven
by the flame detector*, the Return Oil Solenoid Valve (7)
is deenergized, putting full high fire pump pressure on the
Nozzle. Simultaneously, the Three-Way Solenoid Valve (10)
is energized, allowing oil into the Hydraulic Cylinder (9) which
mechanically drives the Air Damper Arm (13) to the high fire
position. The burner operates at full high fire until the system
demand is satisfied. Refer to page 31, Table 8 or page 34,
Table 9 to determine nozzle return flow pressure and flow
rates. This depiction shows the Air Dampers and Hydraulic
Cylinder at the low fire light off position.
The Low-High-Low system is identical to the Low-High-Off
system, except that an additional pressure or temperature
controller is added to the system, which at a selected preset
point will electrically switch the burner to either the high or low
fire position. When the burner is running at high fire and the
controller calls for low fire, the normally closed Oil Solenoid
Return Valve (7) (closed at high fire) is energized, reducing
nozzle pressure to the low fire rate. Simultaneously, the Three-
Way Solenoid Valve (10) is de-energized, allowing oil to flow
out of the Hydraulic Cylinder (9) back to the Pump and driving
the Air Dampers (4) to the low fire position. Responding to load
conditions, the burner can alternate indefinitely between the
low and high fire positions without shutting down. When system
load demand is satisfied, all fuel valves are de-energized and the
Air Dampers are placed in the light off position in preparation
for the next firing cycle. The opening distance of the Air
Dampers is controlled by positioning the Air Damper Drive Arm
(13) relative to the Acorn Nut (16) mounted on the end of the
Hydraulic Cylinder piston rod. The maximum travel is with the
Damper Drive Arm positioned to be in contact with the hydraulic
oil cylinder Acorn Nut at all times. If less travel is desired, set the Air
Damper Drive Arm to allow a gap between it and the Acorn Nut.
(Depending on Air Damper positioning, it may be necessary
to loosen its set screws to attain proper Air Damper opening
distance.) The wider the gap (when the burner is off), the less the
overall travel when going to the high fire position. When setting
the Drive Arm position relative to the Acorn Nut, make certain
that the Air Dampers’ travel is correct for proper combustion at
all firing positions and that there is no binding of the Linkage
or Dampers. Make certain the cast iron Linkage Return Weight
(5) is secure on its Air Damper Arm (17).
*Not shown in this depiction. See page 4, Figure 2
Note 1
The system depicted in Figure 23 uses a Webster Model 22R
oil pump. If your system uses a Suntec H model pump, the
sequence of operation and the oil components would be identical
14 Nozzle
1Oil Solenoid
Valves
Field Piped
Low Oil
Pressure
Switch **
Oil Pump 2
Nozzle Port
Return Port
Inlet Port
Check Valve
(At Tank)*
Shutoff
Valve*
Fusible Link Valve
(If Required by Code)*
Filter*
Check
Valve*
Inlet
Return To
Tank
Field Piped
Pressure
Gauge Test Port 6
* By Others Unless Specified
on Order.
** Burners with Remote Pressure
Atomizing Oil Pumps require a
Low Oil Pressure Switch.
CAUTION:
All field piped components
must be mounted in the proper
location and proper direction of
oil flow.
CAUTION:
Oil supply pressure to Burner
Pump must not exceed 3 PSI
per NFPA Code.
DO NOT USE TEFLON TAPE
15 Pressure Tap
3 Way Oil
Valve 10
NO C
NC
12
#72 Drill
Orifice
7
Return
Oil Valve
Low Fire
Regulating
Valve
9Damper Cylinder
3
1/8” Allen Screw
Under Cap For Oil Nozzle
Pressure Adjustment
Vacuum Gauge
Inlet Port
Optional Return Port
For Simplex Nozzle Use
Alternate Connection to Tee on
Outside of Burner Instead of
Connection to Nozzle Adapter
Figure 23
Typical Oil Burner with Low-High-Off or Low-High-Low Fuel/Air Control Mode Using Webster 22R Oil Pump
8
36
17 8 13
4
7
125
9
16
10
15 12
4
C19
Rev.304

to the Webster 22R system. For additional information on your
specific system refer to the oil piping diagram and the oil pump
manufacturer’s bulletin supplied with the burner.
Note 2
Component operational sequencing will vary with the specific
Flame Safeguard Control being used. Refer to the specific
Flame Safeguard Control bulletin supplied with the burner for
complete information.
MECHANICAL OPERATION: This Low-High-Off system
uses a Two-Step Oil Pump with a Simplex Oil Nozzle (14)
in conjunction with movable Air Dampers (4) to provide
a low fire start and a high fire run sequence. A direct spark
oil ignition system is standard on typical Oil burners (a
gas pilot is standard on Gas/Oil burners), but certain
insurance company codes could require a spark ignited
gas pilot* to provide ignition for the main oil flame. Nozzle
flow rate pressure is taken at the 1/8” Plugged Pump
Pressure Gauge Port (6). The low fire oil rate is set by
adjusting the Oil Pump Low Pressure Regulator (8). The
high fire oil flow rate is set by adjusting the Oil Pump
High Pressure Regulator (3). For both high and low
fires turn the adjustment screws clockwise to increase the
pressure and counterclockwise to decrease the pressure
to the Nozzle. Approximate low fire oil pressures are
100 to 125 psig and high fire, 200 to 300 psig. Both
settings will vary depending upon the specific nozzle
size selected and job conditions. See pages 31-34,
Tables 8 & 9 for specific nozzle pressures and flow
rates. At light off the Main Oil Solenoid Valves (1) are
energized, allowing fuel to the Nozzle. A normally
open pump mounted Oil Solenoid Valve (7) allows a
controlled flow of oil to the Nozzle in accordance with the
14 Nozzle
1Oil Solenoid
Valves
Low Oil Pressure
Switch ** Oil Pump 2
Nozzle Port
Return
Port
Inlet Port
Filter*
Inlet Return
to Tank
Pressure Gauge Test Port 6
* By Others Unless Specified
on Order.
** Burners with Remote Pressure
Atomizing Oil Pumps require a
Low Oil Pressure Switch.
CAUTION:
All field piped components must
be mounted in the proper location
and proper direction of oil flow.
CAUTION:
Oil supply pressure to Burner
Pump must not exceed 3 PSI per
NFPA Code.
DO NOT USE TEFLON TAPE
3 Way Oil Valve 10
NO C
NC
#72 Drill Orifice
7
N.O. Low Fire Solenoid
8
Flat Slot Screw-
driver Low Fire
Pressure Adjust-
ment
9Damper Cylinder
3
Air Bleed
Valves
Optional
Inlet Ports
Oil
Pump
Side
View
Flat Slot
Screwdriver
High Fire
Pressure
Adjustment
Figure 24
Typical Oil Burner with Low-High-Off or Low-High-Low Fuel/Air Control Mode Using a Two-Step Oil Pump (Model C-O)
Field Piped
Check Valve
(At Tank)*
Fuel
Shutoff
Valve*
Fusible Link Valve
(If Required by Code)*
Check
Valve*
Field
Piped
12
pressure setting of the pump low fire adjustment. When
the low fire flame is proven by the flame detector*,
the pump mounted, normally open Solenoid Valve is
energized (closes), putting full high fire pump pressure
on the nozzle. Simultaneously, the Three-Way Solenoid
Valve (10) is energized, allowing oil into the Hydraulic
Oil Cylinder (9) which mechanically drives the Air Damper
Arm (13) to the high fire open position. The burner
operates at full high fire until the system demand is
satisfied. This depiction shows the Air Dampers and the
Hydraulic Cylinder at the low fire light off position.
The Low-High-Low systems are identical to the Low-High-
Off system, except that an additional temperature or
pressure controller is added to the system. At a selected
preset point, it will electrically switch the Oil Valves and
Air Damper components to place the firing rate either in
the low or the high fire run position. When the burner is
running at high fire and the controller calls for low fire, the
normally open pump mounted Solenoid Valve (7) (which
is closed at high fire) is de-energized (opens), reducing
nozzle pressure to the low fire rate. Simultaneously, the
Three-Way Solenoid Valve (10) is de-energized, allowing
oil to flow out of the Hydraulic Cylinder back to the Pump
(2) and driving the Air Dampers (4) to the low fire position.
Depending on load conditions, the burner can alternate
indefinitely between the low and the high fire positions
without shutting down. When system demand is satisfied
all fuel valves are de-energized and the Air Dampers are
placed in the light off position for the next start up. The
Air Damper position for low fire run and light off position
are one and the same in this system. The opening
distance of the Air Dampers is controlled by positioning
the Air Damper Drive Arm (13) relative to the Acorn Nut
(16) mounted on the end of the Hydraulic Cylinder (9)
piston rod. The maximum travel is with the Damper Drive
Arm positioned to be in contact with the hydraulic oil
cylinder Acorn Nut at all times. If less travel is desired, set
the Air Damper Drive Arm to allow a gap between it and
the Acorn Nut. (Depending on Air Damper positioning,
it may be necessary to loosen its set screws to attain
proper Air Damper opening distance.) The wider the gap
(when the burner is off), the less the overall travel when
going to high fire position. When setting the Drive Arm
position relative to the Acorn Nut, make certain that the
Air Damper travel is correct for proper combustion at all
10
13
3
16
1
9
74 17 15
2
6 8
C20
Rev.304

firing positions and that there is no binding of the Linkage or
Dampers. Make certain the cast iron Linkage Return Weight
(15) is secure on its Linkage Arm (17).
*Not shown in this depiction. See page 4, Figure 2.
Note 1
Component operational sequencing will vary with the specific Flame
Safeguard Control being used. Refer to the specific Flame Safeguard
Control bulletin supplied with the burner for complete information.
MECHANICAL OPERATION: The Full Modulation system
uses a two-stage Oil Pump (2) with an internal bypass type
Oil Nozzle (See page 19 & 20, note 1). A Modulating Motor
(4) controls the positioning of the Air Dampers (6) and the
Modulating Oil Valve (5) in the nozzle return line through
mechanical linkage. A direct spark oil ignition system is
standard on typical oil burners (a gas pilot is standard on Gas/
Oil burners) at firing rates up to 45 GPH, with a spark ignited
gas pilot* to ignite the main oil flame above that point. Certain
insurance company codes could require the gas pilot system
on lower input sizes. At main flame light off the normally closed
Oil Valve (1) is energized, allowing oil to flow to the Nozzle. The
Modulating Oil Valve is adjusted to allow a controlled amount
of oil to bypass the Nozzle, which keeps the pressure reduced
to the nozzle for low fire light off. Nozzle oil supply pressure
is set by adjusting the Oil Pump pressure regulator (7). Turn
clock-wise to increase the pressure and counter-clockwise to
decrease the pressure to the nozzle. The low fire nozzle pressures
should be taken at the plugged Oil Pump Gauge Port (8) and
should be approximately 300 PSI with pressure at the Nozzle
Bypass Gauge Port (9) from 60 to 100 PSI, these pressures
varying with nozzle size and job conditions. A typical low fire
oil flow setting on the Modulating Oil Valve would be number
7, but will vary with job conditions. After a brief period of
time for the low fire flame to stabilize, the Modulating Motor
will drive the Fuel/Air Linkage (10) to the high fire position. At
3
Nozzle 1
Oil
Solenoid
Valves
Field Piped
Low Oil
Pressure
Switch **
Oil Pump 2
Nozzle Port
Return Port
Inlet Port
Check Valve
(At Tank)*
Shutoff
Valve*
Fusible Link
Valve (If Required
by Code)*
Filter*
Check Valve*
Inlet
Return to
Tank
Field Piped
Pressure
Gauge
Test Port
* By Others Unless Specified
on Order.
** Burners with Remote Pressure
Atomizing Oil Pumps require a
Low Oil Pressure Switch.
DO NOT USE TEFLON TAPE
CAUTION:
All field piped components must be mounted in
the proper location and proper direction of oil flow.
CAUTION:
Oil supply pressure to Burner Pump must not
exceed 3 PSI per NFPA Code.
9Return Pressure Tap
8
5
Metering Valve
7
1/8” Allen Screw For Oil Nozzle,
Pressure Adjustment Under
Cap
Vacuum Gauge
Inlet Port
Optional Return Port
For Simplex Nozzle Use Alternate Connec-
tion to Tee on Outside of Burner Instead of
Connection to Nozzle Adapter
Check Valve*
Figure 25
Typical Oil Burner with Full Modulation Fuel/Air Control (Model C-O)
46
10
1
79
10
2
8
5
this point the Air Dampers will be full open (or as required
for good combustion) and the Modulating Oil Valve will
be at the closed position and the nozzle bypass line will
be fully closed, putting full oil pressure to the Nozzle.
The Oil Pump Pressure Gauge Port pressure reading will
show approximately 300 PSI and pressures at the bypass
pressure gauge port will be 180 to 225 PSI, although this
will vary with the specific nozzle size being used. Refer
to page 34, Table 9 to determine specific nozzle pressures
and firing rates. A modulating temperature or pressure
controller will now modulate the firing rate to match the
load demand of the system, while maintaining proper
fuel/air ratios. Prior to reaching the system pressure or
temperature operating control cut off point, the burner
should be at or near the low fire operating position. At the
end of the firing cycle, the normally closed Oil Valve will
be de-energized and the Modulating Motor will position the
Air Dampers and Modulating Valve to the low fire position,
ready for the next start up sequence. This depictionshows
the Linkage in the low fire light off position.
See page 22, Figure 27 for linkage adjustment infor-
mation. Also see page 22, Figure 28 for information on
the VaricamTM modulating characterized fuel metering
system.
*Not shown in this depiction. See page 4, Figure 3.
Note 1
Some modulating Low-High-Off and Low-High-Low burners will
be supplied with simplex, rather than internal bypass type, oil
nozzles. The mechanical operation of the simplex nozzle system
is essentially the same as the internal bypass system - except that
low fire oil pressures should be set at 100 to 125 psig (adjust to
suit job conditions) and high fire oil pressures at 280 to 300 psig
at the oil pump nozzle pressure gauge test port. Refer to the
Burner Specification sheet shipped with the burner and/or page
34, Table 9 for high fire oil pressures and flow rates.
The oil pump depicted in the oil flow schematic above is as
manufactured by Webster Electric Company Inc. If the pump
on your burner is not Webster, refer to the oil pump bulletin
shipped with the burner for specific adjustment information.
Also see page 12, Figure 11.
Note 2
Component operational sequencing will vary with the specific
Flame Safeguard Control being used. Refer to the specific
Flame Safeguard Control bulletin supplied with the burner for
complete information.
C21
Rev.304

Gas or Gas/Oil Burner Fuel/Air Premix Adjustment - Gas, Oil or Gas/Oil Burner Diffuser Adjustment
moving it forward decreases the premix air. Generally, the
best (quietest/smoothest) operation is in the full forward
position with minimum premix air. The premix adjustment
is set at the factory in the full forward position. To attain
the best combustion results for specific job conditions,
change position in small increments.
DIFFUSER POSITION ADJUSTMENT
Moving the blast tube diffuser assembly fore or aft on gas
or oil firing will move the flame front (point of retention) in
order to attain the best (quietest/smoothest) combustion
for specific job conditions. If the initial midway point factory
setting does not provide satisfactory results, move fore or
aft in small increments to achieve the best combustion
results. If unit is oil or combination gas/oil, the attached,
flexible copper oil nozzle line will move fore or aft with
the assembly. When firing on oil, moving the assembly
forward will tend to broaden the flame pattern and moving
it back will narrow the flame pattern. Similar results are
obtained on gas, but observation of sound and combus-
tion tests are the best determinants of results on either
gas or oil.
Gas/Air Premix Adjustment Knob Blast Tube Diffuser Position Adjustment
Gas Inlet
Figure 26
FUEL AIR PREMIX
ADJUSTMENT(OPTIONAL)
The adjustable premix blast tube (optional) incorporates an
adjustable gas/air premix within the burner firing head. The
premix configuration is primarily used for cylindrical combus-
tion chambers or high heat release pressurized fireboxes.
Moving the adjustment knob back increases the premix air;
Gas/Oil Linkage Adjustment For Full Modulation Standard System
Typical general linkage arrangement for combination
gas/oil full modulation burner, shown in low fire light
off position. Dotted lines indicate approximately
high fire position. When making adjustments, make
certain the motor can make its full 90ostroke without any
linkage binding.
Driver Arms (A) connected to the Modulating Motor (1)
Jack Shaft (2) will increase the travel of the Driven Arms
(B) as the Linkage Rod (C) ball joint is moved away from
the Jack Shaft. The travel of the Driven Arms will be
increased as the Linkage Rod ball joint is moved toward
the shaft of the driven device.
1. Modulating Motor
2. Jack Shaft
3. Modulating V Port Oil Valve
4. Modulating Butterfly Valve
A. Driver Arms
B. Driven Arms
C. Linkage Rods
Figure 27
Air Damper
Driver Arm
Modulating
Butterfly
Gas Valve
Gas Fuel
Driver Arm
Gas Fuel
Driven Arm
Gas Fuel
Linkage Rod
Cam Screw #13
Gas Fuel Cam Arm
Thread Binding Set Screw
Gas Fuel Cam Follower
Cam
Spring
Cam
Screw
#13
Oil Fuel Driven Arm
Oil Fuel Linkage Rod
Oil Fuel Driver Arm
Modulating Motor Bracket
Jack Shaft Driven Arm
Modulating Motor Driver Arm
Open
Modulating
Motor
Jack Shaft
Linkage Rod
Jack Shaft
Figure 28
Gas/Oil - Detail and Adjustments on Modulating VaricamTM Characterized Fuel Metering System.
For complete adjustment instructions refer to bulletin
VA1588 Varicam Adjustment Instructions included in
the information shipped with the burner.
Air Damper Linkage Rod
Oil Fuel Cam Follower
Air Damper Housing
Oil Fuel Cam Arm
Air Damper Driven Arm
Modulating Oil Valve
Typical Cam Spring
C22
Rev.304

Information on Fuel/Air Modes of Operation for Combination Gas/Oil Units (also see Section 3, page 15)
General Information
Specific adjustments and mechanical operation of the
various modes of fuel/air control for straight gas and
straight oil burners are included in this manual. This
information should be used to properly adjust each fuel
for combination gas/oil units. The following information
is offered as additional guidance.
Gas On/Off System Combined with Oil On/Off System
The air dampers are adjusted and locked in place for the
most efficient operation for both fuels. Refer to the
mechanical operation of the Gas On/Off and Oil On/Off
systems for adjustment details (pages 15, 16 and 17).
4. GENERAL START UP PROCEDURES-ALL FUELS
All Fuels - General Start Up
A thoroughly qualified burner technician should be
employed to provide the initial burner start up, as well as
any subsequent servicing.
A representative of the owner and/or the person or persons
responsible for operating and maintaining the unit
should be present during the initial start up. A service
representative may also be required by the local utility
on gas fired equipment. Instructions regarding the
proper care and maintenance of the unit should be
outlined with these people present.
Before beginning start up, the start up technician should
thoroughly study and become completely familiar with
the exact sequence of operation and all other details of
the specific flame safeguard control system being used.
This information will be found in bulletins printed and
supplied by Honeywell or Fireye. A copy of this bulletin
was supplied with the burner.
After the burner is mounted and all wiring and piping has
been completed, tested and determined to be correct,
the following procedures are recommended:
For combination gas/oil units; the gas side operation
should be set up first to clock the gas meter, allowing
precise gas inputs to be determined. Once the gas ope-
ration is complete, the oil side can be set up easily by
correlating the CO2values of the two fuels. See page
41, Table 13, CO2-O2Ratio Curves for Fuel Oils and
Gases.
If it is anticipated that the Gas/Oil burner will rarely run on
oil; it is recommended that the blower motor driven oil
pump drive coupling be removed - and replaced only
when required for oil firing. If, however, the pump coupling
is left connected to the blower motor, it is essential to
ensure that the pump has a good oil supply, when the
burner is operating on the gas cycle, so that it will not
run dry. Be certain on initial start up that the pump is
adequately primed to prevent against mechanical seizure
caused by lack of oil. The pump warranty will be voided
if the pump is run without adequate oil supply.
1. Make a general inspection tour of the equipment room
to ensure that the installation is complete. Check piping,
controls, and wiring. When using the Alpha System™
Circuit Board, check wiring connections before power-
ing the unit. See page 7 & 8 for connection diagram.
NOTE: L1 Main 115 volt hot incoming power terminal
is located on the lower set of terminals at the bottom
of the main circuit board. The L1 Fused terminal
located on the lower set of terminals is for factory
use only and should not be used for incoming power
connections.
2. Close main and checking gas cocks. Open suction
line manual oil valves and others as appropriate.
3. Tighten all screws on terminal blocks in control cabinet
in case some may have loosened in shipment.
4. Do not secure flame safeguard control into its wiring base
until it has been determined that there are no shorts or
grounds in the system.
5. Check fuses in main panel and in burner control cabinet.
Check wiring to the burner control cabinet for compliance
with the wiring diagram and local codes. Determine that
voltage supply is correct to motor starter line connections
and to control circuit line connections. If a control circuit
transformer is supplied, make certain its primary voltage
matches the line voltage being supplied. (A 230 volt
transformer does not produce proper control voltage when
supplied with 208 volts.)
6. Check breaching and stack to ensure that they are open
and unobstructed.
7. Check blower (and oil pump motor, as applicable) rotation
by momentarily making contact of the motor starters. Proper
rotation is imprinted on the fan housing and (if supplied)
the remote oil pump set assembly.
8. Check operating controls, limit controls, low water cut-off,
flame safeguard control reset, high and low gas pressure
switches (if used) and low fire interlock switch (if used) and
all other applicable interlocks. All contacts should be closed
(an exception will be found on jobs using the low gas
pressure switch; this switch should be open until the main
gas cock is opened). If a low oil pressure switch is used,
its contacts will remain open until the oil pump is running
and the low oil pressure cut-in point is reached.
9. Do not repeatedly recycle the burner, so as to allow any
unburned fuel in the combustion chamber.
10. Specific instructions relative to component sequencing
are provided in the flame safeguard manufacturer’s bulletin
which is included with the documentation shipped with the
burner. Refer to Honeywell and Fireye literature regarding
the clipping of jumpers or setting of DIP switches in
connection with the pilot establishing period, flame failure
action, and air flow switch failure features.
11. Proper test equipment must be used in order to achieve
maximum system operational reliability and fuel efficien-
cies. See page 24 for equipment lists.
12. All fuel/air adjustments should be made to achieve required
input rate, satisfactory combustion test values, flame
stability and appearance.
13. Every new burner start up should employ the use of the
Burner Start Up Information and Test Data sheets on
pages 46 and 47.
Gas On/Off System with Oil On/Off Fixed Air Low Fire Start
System
The air dampers are adjusted and locked in place for the
most efficient high fire operation for both fuels. Smooth light
off on gas is achieved by the use of a slow opening diaphragm
or motorized gas valve, which, once energized, allows gas
flow to steadily increase from the initial light off volume up
to the high fire volume. Smooth light off on oil is achieved by
the use of a solenoid oil valve bypass system which allows
a reduced amount of oil to be burned at light off and then
switching to the high fire rate once the low fire has been
established. Refer to the mechanical operation of the Gas
On/Off system and the Oil Fixed Air Low Fire Start system
C23
Rev.304

General Information
Power Flame Type C oil burners are of the pressure atom-
izing forced draft type, using a single simplex or bypass
type nozzle system. On/Off burners use a simplex nozzle.
Fixed air low fire start burners use a simplex nozzle with
a bypass valve to allow reduced oil nozzle pressures at
light off. Low/High/Off and Low/High/Low burners have
movable air dampers and may use a single simplex or
bypass type oil nozzle with a bypass valve to allow reduced
oil pressures at light off and at low fire. Modulating burners
have movable air dampers and use a single simplex or
bypass type oil nozzle with a proportioning metering valve
in the nozzle return line to allow modulated fuel inputs from
low to high fire.
Some applications may require the burner to function at the
low end of its rated capacity. As a result, the two combustion
air inlets may supply more air than is required for efficient
combustion. It may therefore be desirable to operate
the system using only one combustion air inlet and one
combustion air inlet damper.
Notice
Refer to page 23 General Start Up Procedures - All Fuels and Section 3 for mechanical operation detail of specific mode of
operation. Combination Gas/Oil systems should also refer to page 23, Information on Fuel/Air Modes of Operation for Combination
Gas/Oil Units.
This may be accomplished by removing cross connect-
ing linkage between dampers and locking the unused
damper in a fixed position.
One way of locking the damper is to use a 10-24 machine
screw through the hole in the linkage arm, and drill and
tap the air inlet housing or use two nuts on the screw and
let the screw bear against the air inlet housing.
Air diffuser movement (fore and aft) may be necessary to
produce the best flame pattern or smoothest operation.
See page 22, Gas, Oil or Gas/Oil Burners Diffuser Adjust-
ment, for further information.
Gas and Gas/Oil burners for Scotch marine and other
selected applications incorporate a gas/air premix
adjustment. This adjustment is identified by diametrically
opposed adjustment knobs on the blast tube. See page
22, Gas or Gas/Oil Burner and Fuel/Air Premix Adjustment for
further information.
Burner Start Up Sequence
1. Check oil and gas piping (if applicable) for leaks, and
check all controls for compliance with codes and
insurance requirements.
2. Check all linkages. If the system is a packaged burner/
heat exchanger system, the linkage was probably set
when the system was fire tested at the heat exchanger
manufacturing factory. It should, however, be checked
to ensure that it was not damaged in shipment. If the
system is a conversion unit (burner and heat exchanger
are mated in the field), the linkage will have to be set
to suit the particular operating conditions.
3. Do not secure flame safeguard control into its wiring
base until it has been determined that there are no
shorts or grounds in the system.
4. Install oil pressure and vacuum gauges. See Section 3
for mechanical operation and oil gauge location for the
specific system. Check suction line to be sure manual
valve is open and that check valves are opening in the
proper direction of oil flow. Check oil filter for tightness.
There should be no manual valve in the return line from
pump to tank.
5. Direct Spark Oil Ignition. Remove oil nozzle gun and
check electrode settings and ensure that oil nozzle size
is correct. Electrode gap should be approximately
1
/
8
” and set forward to correspond with the nozzle
spray angle. Do not set electrodes so that oil can
impinge on them. See pages 35 and 36 for detailed
information on oil ignition systems.
6. Gas Pilot Oil Ignition. Remove the pilot assembly
and check for the proper setting of the ignition
electrode spark gap. Install a manometer or 0-10”
W.C. gas pressure gauge in the pilot gas pressure
test port. See page 39 for details on gas pilot
adjustments. Disconnect the pilot gas line at the inlet
to the pilot gas pressure regulator and bleed air out
of the pilot line. Make certain that the gas pressure to
the pilot regulator does not exceed the regulator or
pilot solenoid valve rating. When bleeding air from
the pilot line system, do not allow the venting of
gas into the room.
7. Install required systems measuring devices:
A) appropriate flame signal meter to the flame
safeguard control
B) stack thermometer, CO
2
and Smoke Test
sample line in the breaching
C) draft gauge to the combustion chamber
test point
8. With the burner panel control switch in the Off
position, apply power to the burner through the main
burner disconnect switch. Switch the burner panel
On/Off switch to the On position momentarily to
determine that the blower motor (and separate oil
pump set motor, if supplied) is running in the right
rotation.
9. Appropriate steps must be taken to transfer the oil
from the tank to the burner. It is imperative that the
system be primed prior to operation. The system
priming may be achieved by closing the manual
valve in the oil suction line and priming the oil pump
through the pump gauge pressure port. Priming can
also be accomplished through the oil filter on the
suction line, if it is of the removable top type. When
replacing the oil filter cap, be sure to attain a vacuum
tight seal. Start the burner with the suction line manual
valve closed. Let the burner run until the vacuum
gauge indicates a high vacuum, then quickly open
the manual valve in the suction line. This combination
of priming and high suction should pull the oil from
the tank to the burner, provided that there are no
leaks and the line is properly sized. See page 12
Figure 10 for proper line size.
6. OIL START UP
C28
Rev.304

10. Refer to the burner wiring diagram and flame
safeguard control information supplied with the burner to
determine the specific firing sequence relating to limit
and interlock circuits.
11. Set the air damper approximately
1
/
4
” open and start
the burner. The ignition circuit will be energized after
the blower prepurge period (if supplied) has been
completed and all limit and other interlock circuits have
been closed. If the unit has a gas pilot, allow it to come
on and adjust it for proper ignition and flame signal.
For flame safeguard controls having a timer Stop/Run
test switch, place the switch in the Stop position, caus
ing the ignition timing sequence to stop while air and
gas pressure adjustments are being made. See page
39 for details on gas pilot ignition adjustments.
Cycle the burner several times to make certain the pilot
is operating reliably. Shut the pilot gas cock and cycle
the burner through prepurge. With the gas shut off,
the pilot valve and ignition transformer will energize,
but there will be no pilot and the unit will shut down
on safety lockout.
There should be no evidence of a flame signal reading
or should the main oil solenoid valve attempt to open.
12. When a Gas Pilot is used to ignite the main oil, there
will be a period of time when only the pilot will be on.
The flame scanner must first detect the pilot Then, in a
given number of seconds, the main oil solenoid
valve will be energized. For direct spark ignited oil
units, the ignition spark and main oil solenoid valve
will be energized at the same time. As soon as the
oil flame is detected by the flame scanner, the ignition
spark will be de-energized (interrupted ignition), unless
the burner is equipped with intermittent spark operation,
which keeps the spark on during the burning cycle.
13. For burners equipped with gas pilots, perform an
initial Spark Pickup Test. With the pilot gas cock
closed, the burner will go through a blower prepurge
period, after which the gas pilot ignition transformer will
be energized, although no pilot will be established. (At
no time should there be any flame signal reading, nor
should the main gas valve attempt to open.) At the end
of the pilot trial for ignition and blower purge period, the
flame safeguard control should shut the system down in
a safety lockout mode, requiring manual reset of the
flame safeguard control to restart burner. If a flame
signal is detected, verify the flame retention tab and
ignition electrode are properly positioned, per
Figures 33-37.
14. Pilot Verification. Critical. See Page C26, Item 12.
15. If the burner is direct spark ignited, either remove the
flame scanner from its sight pipe or electrically dis-
connect the main oil solenoid valve and start the burner.
In either of the above tests, the flame safeguard control
will not detect any flame and should go into a safety
lockout mode requiring manual reset of the flame
safeguard safety lockout switch.
16. There must be no indication of oil pressure at the nozzle
until the main oil valve is programmed to open. Should
a pressure reading be obtained prior to that time, it is
an indication that the main oil valve has been mis-wired
or is leaking.
17. Restart the burner and allow normal sequencing to
bring on gas pilot ignition or the direct spark ignition.
Once the main solenoid oil valve is energized, the oil
flame should be established immediately. If not, shut
the system down and make corrections as required.
Do not repeatedly recycle the burner, such as to allow
any accumulation of unburned fuel in the combustion
chamber.
18. For small On/Off burners with a simplex nozzle,
adjustments consist primarily of attaining correct fuel/air ratios.
Adjustments should be set to obtain11-12
1
/
2
% CO
2
and no
more than a #2 smoke (Bachrach). The burner can usually
be set to burn at a 0 smoke reading. Oil pump pressures
will be set anywhere from 200 to 300 psig. See page 34,
Table 9 for additional information.
19. Fixed Air Low Fire Start burners with simplex nozzles
require correct fuel/air ratios for high fire and should
be set with no more than a #2 smoke at high fire with
11 - 12
1
/
2
% CO
2
. 0 smoke should be attainable. Low
fire nozzle pressures are set to achieve smooth light
off with the air dampers fixed in the operating (high fire)
position. See page 34, Table 9 for additional
information. High fire nozzle pressures will be from
200 to 300 psig.
20. Gas On/Off System with Oil Reduced Air, Low Fire
Start RALFS. See page 18, Figure 22.
21. Low/High/Off or Low/High/Low modes of operation
(both having automatic air dampers) should have initial
adjustments made at the light off position. See Section
3 for mechanical operation of the specific system. After
the light off fuel/air adjustments are made (which on a
Low/High/Low oil burner is the same as the Low Fire
position), run the burner to the high fire position and
make adjustments as required for good operation.
Adjustments should provide 11 - 12
1
/
2
% CO
2
with no
more than a #2 smoke (0 smoke is usually attainable)
at high fire and 8 - 10% CO
2
with no more than a #2
smoke on low fire (0 smoke is usually attainable) for
Low/High/Low systems. For systems with two-step
pumps using simplex nozzles or internal bypass nozzles,
the oil pressures at the nozzle supply pump gauge port
will generally be from 100 to 125 psig at low fire and 200
to 300 psig at high fire. For systems with pumps that
do not have the two-step operation and employ the
internal bypass nozzle, the nozzle supply pump gauge
port will generally be from 270 to 300 psig at both low and
high fires. The nozzle bypass line pressure at low fire will
generally be from 60 to 125 psig and 180 to 225 psig at high
fire. Tighten all linkages and permanently mark all settings.
See page 31, Table 8 and page 34, Table 9 for additional
information.
22. Intermittently operate the burner until the water is warm in
the boiler, or follow specific initial firing recommendations
provided by the heat exchanger manufacturer.
23. See items 35 through 37 in this section for recommended
limit control and other control devices operational checkout.
Burners designed for Full Modulation operation. After
completing procedures as appropriate in items 1-15 above
proceed with modulating adjustments as follows:
24. The modulating motor is connected by linkage to the air
inlet dampers and a fuel metering valve located in
the oil nozzle return line controls a modulated fuel input
from low to high fire. Each control point has its own multi
position arm, so that proper air/fuel ratios can be
achieved throughout the entire firing range. Initial
adjustments should be made at the low fire position (low
fuel/air flow). All Power Flame burners are factory tested
and adjusted. However, to determine that the metering
valve is, in fact, in the low fire position, observe the
pointer on the metering valve shaft. The pointer must
be pointing toward the #6 or #7 position on the dial for
North American valves, or 4
1
/
2
to 9 on Hauck valves. As
the burner runs from low to high fire, it will proceed from
the low fire setting towards the 0 position on the dial
(i.e., the valve will be fully closed at high fire).Refer to
page 22, Figure 27 for linkage adjustment information
and page 22,Figure 28 for adjustment information on
the Varicam
TM
characterized fuel metering system.
C29
Rev.709

25. Turn the burner on and let it advance to the main flame
light off position, taking action as necessary to hold
the linkage at the low fire position by using a manual
potentiometer or electrically disconnecting the
modulating motor. Power Flame burners are test fired
at the factory, and linkage adjustments for modulation
are made at that time. Note that the factory settings
relate to good operation while firing into open test pits,
and will therefore not normally relate directly to the
absolute fuel/air ratios while firing under specific field
conditions. It is suggested that the factory settings be
noted and marked on the linkage prior to proceeding
with final adjustment. This will allow a return to those
settings as initial reference points, if need be.
26. On internal bypass nozzle systems, oil pressure at the
pump nozzle port will generally be between 270 and
300 psig from low to high fire. At certain input ranges
of burner models C4 and C5, nozzle pressure may fall
off to approximately 240 psig when in the low fire
position. For oil pressure settings on simplex nozzle
systems, refer to page 34, Table 9.
27. On internal bypass nozzle systems, typical low fire
nozzle bypass line pressures will generally be in the
area of 60 to 90 psig. High fire nozzle bypass line
pressures will generally be in the range of 200 to 225
psig, but these pressures can vary, depending upon the
nozzle selected for a particular firing application. Refer
to page 31, Table 8 for specific nozzle bypass line
pressures. Refer to page 34, Table 9 for simplex nozzle
systems and pressures.
28. With the burner in the factory set low fire position,
adjust air and fuel linkage to good fuel/air ratio low fire
settings (8 - 10% CO
2
and #0 - #2 smoke reading).
Mark the linkage at the new settings.
29. Increase the firing rate to the midway point. Set the
fuel/air ratios to achieve good combustion values (9 -
11% CO
2
and #0 to #2 smoke reading). Mark the
linkage as a reference point for this new mid-fire
position.
30. Increase the rate to the high fire position and repeat the
tests done for the mid-point adjustment. Results should
be in the area of 12
1
/
2
% CO
2
and no more than #2
smoke. The metering device setting and air damper
openings should be marked and noted to obtain the
high fire reference points.
31. Operate the modulating lever arm on the modulating
motor through the three previously determined reference
points. Minor setting modifications may be required to
ensure that the reference points are acquired.
32. Tighten (finger tight) the hex bolt to the linkage rod at
the swivel on the modulating motor driver arms, and
run the motor through its full travel to ensure that
linkage is free and that the limits on the metering
device and air dampers are not exceeded.
33. Intermittently operate the burner until the water is
warm in the boiler, or follow specific initial firing
recommendations provided by the heat exchanger
manufacturer.
34. Tighten all linkages and permanently mark settings.
35. Limit control check should be made as follows:
A) Permit the burner to run until the limit control
settings have been reached.
B) The burner should turn off when the set temperature
or pressure has been reached. If the burner is Low/
High/Low or Modulating, set the controls so that the
burner will go to the low fire position before the
operating limit control turns the burner off.
C) After the differential pressure or temperature
drop, the burner should start automatically.
D) With the unit running normally, open the
blowdown valve and remove water to the point
below the low water cutoff setting. The burner
should turn off and restart automatically when
the proper water level is re-established. (If manual
reset type low water cutoff is used, it will have
to be reset.)
E) Set and check operation of:
(1) Low Oil Pressure Switch (if supplied). Set
at 80% of low fire oil pressure. Check visually,
or test electrically to confirm that circuit
opens at the proper oil pressure.
(2) Blower Combustion Air Flow Switch (if
supplied).
(a) Shut burner power off.
(b) Disconnect both wires at the air flow
switch and temporarily clip them
together. Make sure that they cannot
ground against anything, since they
will be powered with 110 volts during
the test.
(c) Put a continuity meter across the two
terminals.
(d) Disconnect the wire to the main
automatic oil valve.
(e) Start the blower motor. The meter
should read electrical continuity as soon
as the blower starts.
(f) Disconnect the blower motor lead wire,
or open the main power disconnect
switch to the burner. Within 4 to 5
seconds after the blower motor is de-
energized, the meter should indicate an
open air flow switch circuit (no continuity).
(g) If the switch does not open in 4 to 5
seconds, readjust accordingly. Turn the
air flow switch adjustment screw
clockwise to shorten cut-off response
time, and counter-clockwise to lengthen
cut-off response time.
(h) Turn the burner power off. Remove the
shorting clip from the two disconnected
wires and let them hang loose. (They
will be powered with 110 volts, so do
not let them ground out.)
(i) Reconnect the wire to the main
automatic oil valve. Turn the burner on.
With the air flow switch wires discon-
nected, the burner should go into a
purge cycle, but neither the ignition nor
the main fuel valve circuits will be
energized. If they do energize, there is
a wiring problem. Correct as required.
(j) Turn power off. Reconnect the air flow
switch wires to the air flow switch
terminals. Place burner back into
normal operation.
(3) All burner and heat exchanger controls and
operating devices.
36. The Owner’s Operating Instructions, page 51 of this
manual, should be posted in a clearly visible location
close to the burner.
37. If the burner operation is abnormal, refer to Section
7 Trouble Shooting Suggestions, as well as trouble
shooting information in the flame safeguard
C30
Rev.709

manufacturer’s bulletin shipped with the burner. It is also
strongly suggested that all test procedures outlined in the flame
safeguard control manufacturer’s bulletin be conducted.
38. Complete the Burner Start Up Information and
Test Data sheets on pages 46 and 47.
7. SERvICING AND COMPONENT ADjUSTMENTS
General Information on Internal Bypass Oil Nozzle Systems
1. The system is designed to use 300 PSI pressure at the
nozzle inlet at low and high fire (and throughout the
range on modulating systems). The firing rate is changed
by an adjustable bypass arrangement that allows more
or less oil to bypass the nozzle and flow to the return line.
Low fire pressures at the bypass pressure test tee will
generally be from 60 to 100 PSI, with high fire bypass
pressures from 180 to 225 PSI. These pressures will vary
depending upon the nozzle size selection and specific
job firing conditions. See this page, Table 8 for flow rates,
sizing and pressure information.
2. Smoky fires with apparent large droplet size in the spray
pattern are generally caused by low nozzle or return flow
pressures. To properly check the system, it is necessary
to verify both nozzle supply and return pressures. Also
check to make certain that the nozzle adapter and
strainer are not partially plugged.
3. Careless cleaning or handling of the nozzle may
damage the orifice, causing heavy streaks in the oil
spray. This will also show up as large droplets or sparks
in the flame.
4. Off center fires, low bypass line pressures and safety
lockouts (due to poor spray pattern and ignition failure)
may result from plugged slots in the nozzle distributor
head. When such situations are observed, the
nozzle should be removed, disassembled and
cleaned.
5. Excessive after squirt of oil is caused by air in the
system. Be sure air is not trapped in pressure
gauges, overhead oil lines or fittings. A leaking
check valve on the bypass return line from the
nozzle can create the same effect.
6. The Teflon seal should stay on the nozzle when
servicing. On some sizes of burners using Delavan
30630 and 30637 Series nozzles, the Teflon seal
stays in the nozzle adapter. If it is damaged
through careless handling, the resulting leak will
cause an increase in the burning rate, when the
bypass line is closed at high fire.
7. High turn down ratios are a distinct advantage of
internal bypass systems. It is possible, however,
to adjust for a low fire so small that the flame is
being chilled. The fire will look excellent and
appear bright and uniform, but a combustion
efficiency test will reveal high smoke content and
low CO2. To correct this situation, increase the oil
flow or decrease the air, or both. Be sure to test
with proper instruments to ensure good, clean
efficient combustion throughout the firing range.
HAGO
Nozzle Size
100 PSIG
Nominal
Rating GPH
#2 Fuel Oil
By-Pass
(Return)
Closed
Approx. High
Fire Rate
GPH
300 PSIG
By-Pass
(Return)
Closed
Approx. High
Fire By-Pass
(Return)
Pressure
PSIG By-Pass
(Return)
Closed
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Supply Pressure to Nozzle 300 PSIG at All Rates*
Reduced Firing Rates
4.5 7.3 207 180 5.5 150 4.4 120 3.1
5.0 8.5 196 150 5.9 120 4.4 90 2.8
5.5 9.0 209 180 7.0 150 5.2 120 3.8
6.0 10.2 190 150 7.0 120 5.1 90 3.1
6.5 10.8 195 150 7.6 120 5.2 90 3.4
7.0 11.5 202 150 7.1 120 5.1 90 3.5
7.5 12.6 181 150 10.0 120 7.1 90 4.8
8.0 13.3 197 180 11.6 150 8.2 120 5.5
9.0 15.2 200 180 12.5 150 8.9 120 6.0
9.5 15.9 178 150 12.0 120 8.0 90 5.1
10.0 17.2 202 180 13.8 150 9.6 120 6.3
Table 8
Internal Bypass (Return Flow) Nozzle Data
Figure 29
Internal Bypass Oil Nozzle Components
Nozzle Tip
Distributor
Strainer
Combination Locknut & Strainer Support
Seal Bushing
Adapter
C31
Rev.709

4.5 7.8 205 180 7.7 60 3.4 - -
5.0 8.2 195 180 7.6 120 4.9 60 3.6
5.5 9.3 180 120 4.6 60 3.5 - -
6.0 10.4 215 180 5.9 120 4.4 60 3.1
6.5 11.5 225 180 6.3 120 4.8 60 3.6
7.0 10.6 220 180 7.9 120 5.4 60 3.6
7.5 12.3 205 180 7.6 120 5.4 60 4.1
8.0 12.5 200 180 7.7 120 5.0 60 3.5
9.0 14.4 200 180 9.1 120 5.9 60 3.9
9.5 15.4 210 180 9.4 120 6.2 60 4.3
10.5 16.0 220 180 9.8 120 6.5 60 4.3
12.0 19.4 210 180 12.5 120 8.1 60 4.9
13.5 23.3 210 180 18.5 120 10.8 60 6.6
15.5 25.5 220 180 13.9 120 9.0 60 6.8
17.5 28.2 225 220 22.4 180 17.0 120 10.9
19.5 30.6 235 220 23.6 180 17.4 120 10.3
21.5 33.5 240 220 26.4 180 19.4 120 11.9
24.0 35.1 230 220 33.4 180 24.3 120 14.4
28.0 48.7 215 180 40.2 120 21.1 60 11.1
30.0 51.6 225 220 50.6 180 38.0 120 23.2
35.0 58.5 200 180 38.0 120 32.6 60 15.7
40.0 68.3 190 180 54.3 120 40.5 60 22.2
45.0 76.2 180 180 66.0 120 49.6 60 29.4
50.0 83.9 165 120 61.9 - - - -
Nozzle Size
100 PSIG Approx. High Approx. High
Nominal Fire Rate Fire By-Pass
Rating GPH GPH (Return) Approx. Approx. Approx. Approx. Approx. Approx.
#2 Fuel Oil 300 PSIG Pressure By-Pass Firing Rate By-Pass Firing Rate By-Pass Firing Rate
By-Pass By-Pass PSIG By-Pass (Return) GPH (Return) GPH (Return) GPH
(Return) (Return) (Return) Pressure Pressure Pressure
Closed Closed Closed PSIG PSIG PSIG
MONARCH
Supply Pressure to Nozzle 300 PSIG at All Rates*
Reduced Firing Rates
HAGO
Nozzle Size
100 PSIG
Nominal
Rating GPH
#2 Fuel Oil
By-Pass
(Return)
Closed
Approx. High
Fire Rate
GPH
300 PSIG
By-Pass
(Return)
Closed
Approx. High
Fire By-Pass
(Return)
Pressure
PSIG By-Pass
(Return)
Closed
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Supply Pressure to Nozzle 300 PSIG at All Rates*
Reduced Firing Rates
10.5 17.5 202 150 11.4 120 8.0 90 5.4
11.0 19.3 203 150 11.4 150 11.4 120 7.9
11.5 20.0 192 180 17.8 150 12.8 120 8.5
12.0 20.1 194 180 18.1 150 13.0 120 9.1
12.5 21.6 196 180 18.6 150 13.4 120 8.9
13.0 22.2 205 180 17.8 150 12.9 120 8.8
13.5 23.2 192 180 21.0 150 14.8 120 10.5
14.0 24.0 208 180 18.9 150 13.3 120 8.5
14.5 24.6 207 180 18.6 150 14.1 120 9.2
15.0 26.0 199 180 21.8 150 15.6 120 10.4
16.0 26.8 190 180 24.9 150 18.2 120 11.9
17.0 29.0 206 180 23.4 150 16.9 120 11.5
17.5 29.2 204 180 24.4 150 18.1 120 12.2
18.0 29.8 206 150 20.0 120 15.3 90 11.1
19.0 32.4 202 180 27.8 150 20.2 120 14.1
19.5 33.4 185 150 24.3 120 17.1 90 11.3
20.0 35.2 185 150 26.5 120 18.3 90 12.1
21.0 36.4 190 150 26.2 120 18.8 90 13.1
21.5 37.0 192 150 26.8 120 18.4 90 12.8
22.0 37.3 192 150 26.0 120 19.6 90 13.6
24.0 41.6 190 150 29.7 120 21.7 90 15.1
26.0 42.4 198 150 29.5 120 22.1 90 15.8
28.0 46.0 198 150 31.6 120 23.8 90 17.9
30.0 49.3 196 150 35.9 120 28.3 90 21.6
32.0 53.0 192 150 40.3 120 31.2 90 23.9
35.0 57.1 205 150 40.1 90 26.1 70 22.5
40.0 65.3 198 150 49.3 90 31.9 70 27.8
45.0 74.6 188 150 61.9 90 43.8 70 39.7
50.0 83.0 175 150 73.7 90 51.2 70 46.1
C32
Rev.304

DELAVAN VARI-FLO 30630 and 30637
Nozzle Size
300 PSIG
Nominal
Rating GPH
#2 Fuel Oil
By-Pass
(Return)
Closed
Model
Number
Approx.
High Fire
Rate
GPH 300
PSIG
By-Pass
(Return)
Closed
Approx.
Alternate
Nozzle
Pressure
PSIG
Approx.
GPH
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Approx.
By-Pass
(Return)
Pressure
PSIG
Approx.
Firing Rate
GPH
Supply Pressure to Nozzle 300 PSIG at All Rates Except Alternate Firing*
Alternate Firing
Approx. High
Fire By-Pass
(Return)
Pressure
PSIG
By-Pass
Return)
Closed
Nozzle Data
35.0 #30630 35.0 157 - - 140 32.0 100 18.7
37.5 #30630 37.5 180 - - 140 28.6 100 13.8
40.0 #30630 40.0 191 - - 140 25.4 100 16.7
45.0 #30630 45.0 192 - - 140 30.6 100 16.5
50.0 #30630 50.0 185 - - - - 86 16.7
55.0 #30630 55.0 182 - - 91 18.3 - -
60.0 #30630 60.0 178 - - 94 20.0 - -
65.0 #30630 65.0 165 - - 85 21.7 - -
70.0 #30630 70.0 174 - - 88 23.3 - -
80.0 #30630 - 154 265 75 78 25.0 - -
80.0 #30637 - - 260 74 85 24.7 - -
80.0 #30637 - - 280 78 90 26.0 - -
80.0 #30637 80.0 157 - - 65 27.0 - -
90.0 #30637 - - 260 83 90 27.7 - -
90.0 #30637 - - 280 86 85 28.7 - -
90.0 #30637 90.0 165 - - 80 30.0 - -
100.0 #30637 - 136 260 93 90 31.0 - -
100.0 #30637 - 151 280 97 90 32.0 - -
100.0 #30637 100.0 165 - - 90 32.3 - -
125.0 #30637 - 161 260 115.0 90 38.0 - -
125.0 #30637 - 163 280 120.0 90 39.0 - -
125.0 #30637 125.0 175 - - 90 41.0 - -
150.0 #30637 - 161 260 140.0 90 45.0 - -
150.0 #30637 - 163 280 145.0 90 50.0 - -
150.0 #30637 150.0 175 - - 90 56.0 - -
*When Supply Pressure to Nozzle is Lower Than 300 PSIG the By-Pass(Return) and Firing Rates Will be Reduced Somewhat.
Consult Factory for Further Information.
* When Supply Pressure to Nozzle is Lower Than 300 PSIG the By-Pass (Return) and Firing Rates Will be Reduced Somewhat.
CConsult Factory for Further Information.
Nozzle Size
100 PSIG Approx. High Approx. High
Nominal Fire Rate Fire By-Pass
Rating GPH GPH (Return) Approx. Approx. Approx. Approx. Approx. Approx.
#2 Fuel Oil 300 PSIG Pressure By-Pass Firing Rate By-Pass Firing Rate By-Pass Firing Rate
By-Pass By-Pass PSIG By-Pass (Return) GPH (Return) GPH (Return) GPH
(Return) (Return) (Return) Pressure Pressure Pressure
Closed Closed Closed PSIG PSIG PSIG
4.5 7.5 162 120 5.0 100 4.0 70 3.0
5.0 8.5 136 120 7.0 105 6.0 75 4.0
5.5 9.2 150 130 8.0 120 7.0 80 4.0
6.0 - - - - - - - -
6.5 10.8 160 160 9.0 120 7.0 80 4.0
7.0 12.0 141 125 10.0 110 8.0 67 4.0
8.0 13.0 158 130 10.0 120 8.0 85 5.0
9.0 15.0 132 100 10.0 90 7.5 60 5.0
9.5 15.0 158 120 10.0 110 7.5 80 5.0
10.0 16.0 150 - - - - - -
12.0 20.0 154 118 16.0 94 12.0 70 8.0
14.0 23.0 160 120 17.0 100 11.0 85 8.0
16.0 26.0 144 115 17.0 100 15.0 75 10.0
18.0 30.0 165 135 22.0 110 15.0 80 10.0
20.0 32.0 160 120 24.0 100 18.0 80 14.0
22.0 36.0 155 120 27.0 100 20.0 82 15.0
24.0 41.0 144 120 30.0 100 25.0 72 15.0
26.0 43.0 150 100 35.0 100 27.0 65 15.0
28.0 47.5 148 120 40.0 100 30.0 65 16.0
30.0 51.0 138 85 40.0 75 30.0 50 17.0
35.0 60.0 175 115 40.0 90 30.0 60 20.0
40.0 68.0 115 70 45.0 50 35.0 20 23.0
45.0 76.0 166 120 60.0 85 40.0 50 25.0
50.0 85.5 - - - - - - -
DELAVAN VARI-FLO 33769
Supply Pressure to Nozzle 300 PSIG at All Rates*
Reduced Firing Rates
C33
Rev.304

Table 9
OIL NOZZLE FLOW RATES
Simplex Nozzle System (Monarch PLP or Equivalent Solid or Semi Solid)
Flow Rate vs Pressure
Oil Nozzle Servicing
1. Nozzles used on Power Flame Type C burners are of two
types: simplex and internal bypass. The simplex nozzle
is normally used on smaller burners in the three to eight
gallons per hour range. The bypass nozzle is used for
larger inputs requiring higher turndown or more
sophisticated air/fuel control. Both types of nozzles have
GPH ratings stamped on the side. Stamped ratings are
based on 100 psig except models 30630 and 30637
which are based on 300 psig. The burners operate in the
300 psig range. See pages 31 through 34, Tables 8 and
9 for flow rates, pressure and sizing information.
2. When removing or replacing the oil nozzle and electrode
assembly, take care to prevent damage to the ignition
wire.
3. The nozzles should be removed from the nozzle adapter
by use of the proper wrench. They should be disas-
sembled and thoroughly cleaned with a liquid solvent
(preferably non-flammable) and a brush.
4. Do not use a screwdriver, wire brush or similar metallic
objects to clean nozzles. Damage to orifices or spray
slots result in off-center or sparky fires.
5. The nozzle should be seated firmly in the nozzle
adapter to prevent leaks.
6. If a nozzle is damaged or burned, replace it.
7. The entire oil tube and nozzle assembly (the oil drawer
assembly) may be removed for ease of service.
8. When cleaning and taking the nozzle apart, do not
force it.
9. For additional information on bypass nozzles, see
page 30. Note that the Teflon seal in the Monarch
F80BPS and Delavan 33769 nozzles is an integral
part of the nozzles and that if the seal is removed
accidentally, the nozzle must be replaced. On the
Delavan 30630 and 30637 nozzles, the seal normally
remains in the nozzle adapter. When the nozzle is
removed from the adapter, the seal should also be
removed and replaced with a new seal.
Oil Pump or Oil Flow Problems and Typical Solutions
NO OIL DELIVERED
1. Reversed pump rotation
2. Suction lift too high (See page 12, Figure 10)
3. Air leak in suction line
4. Pump not primed, or has lost prime
5. Pump coupling not installed properly
6. Pump defective
7. Line plugged
8. Valve closed
NOISY PUMP
1. Air leak in suction line
2. Pump not securely mounted
3. Vibration caused by bent shaft or misalignment
4. Pump overloaded
5. Suction line vacuum so high that vapor forms
within the liquid (see page 12, Figure 10)
Capacity in GPH #2 Oil
100#
Nominal
Rating
2 2.1 2.3 2.4 2.6 2.7 2.9 3.0 3.1 3.2 3.3
2.5 2.6 2.8 3.0 3.2 3.4 3.6 3.7 3.8 4.0 4.1
3 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.7 4.8 5.0
3.5 3.7 3.9 4.2 4.5 4.7 4.9 4.2 5.4 5.8 5.9
4 4.2 4.5 4.8 5.1 5.4 5.6 5.9 6.2 6.4 6.7
4.5 4.7 5.0 5.4 5.7 6.1 6.3 6.6 7.0 7.2 7.4
5 5.3 5.6 6.0 6.4 6.8 7.1 7.3 7.7 7.9 8.2
5.5 5.7 6.1 6.5 7.0 7.3 7.7 8.0 8.4 8.6 9.1
6 6.3 6.7 7.2 7.7 8.1 8.5 8.8 9.2 9.5 9.9
6.5 6.8 7.2 7.9 8.3 8.8 9.2 9.5 10.0 10.3 10.7
7 7.3 7.9 8.3 9.0 9.4 9.9 10.3 10.7 11.2 11.4
7.5 7.8 8.5 8.9 9.6 10.0 10.5 11.0 11.5 11.9 12.2
8 8.3 9.1 9.5 10.3 10.8 11.3 11.8 12.3 12.8 13.0
9 9.4 10.1 10.8 11.5 12.0 12.8 13.2 13.9 14.4 14.8
10 10.4 11.2 12.0 12.8 13.4 14.2 14.7 15.4 16.0 16.6
11 11.5 12.5 13.3 14.2 15.0 15.6 16.2 17.0 17.7 18.2
12 12.5 13.6 14.5 15.3 16.2 17.0 17.7 18.5 19.2 19.8
120# 140# 160# 180# 200# 220# 240# 260# 280# 300#
C34
Rev.304

Ignition Electrode &
Porcelain Insulator
Stainless Steel
Fan Diffuser
1/16”
1/8” N.P.S. Brass Pipe
Ignition Electrode Support
1/4” From Nozzle Tip to Electrode Tip
Nozzle
Typical Electrode Setting
For Most Non-Pressurized
Combustion Chambers
5/16”
1/4”- 5/16”
5/16”
5/16”
3/16”
Typical Electrode Setting
For Most Pressurized
Combustion Chambers
Figure 31
Oil Drawer Assembly Jacobs Ladder Electrode Settings
Figure 30
Oil Drawer Assembly Tip Point Ignition Electrode Setting
Cable Routing
Bracket
Ignition Electrode &
Porcelain Insulator
(Optional)
Certain OEM applications may require
alternate settings. Setting of electrodes
closer to center of nozzle and/or farther
forward may be required.
Stainless Steel
Fan Diffuser
Nozzle
1/8” to 3/16” Gap
Ignition Electrode
Support
1/8” N.P.S. Brass Pipe
Stainless Steel
Fan Diffuser
5/16” for
60oNozzle
1/4” From Nozzle
Tip to Electrode
Tip
3/8” for
80oNozzle
5/16”
Direct Spark Oil Ignition Adjustments
1. The ignitor assembly should be removed and
cleaned regularly. The porcelain insulators should
be kept clean and must be replaced if cracked.
2. The spark gap must be set in accordance with the
dimensions noted. (Refer to Figures 30, 31, 32).
Ensure that the distance between the electrodes and
the nozzle (or diffuser) is greater than the spark gap.
3. The electrodes should not extend closer than 1/8” to
the spray angle of the nozzle to prevent carboning.
A nozzle spray angle check card is available and
may be used to check electrode position.
4. The high tension wires and clips between the
transformer and ignitor electrodes should be
checked periodically for deterioration.
PUMP LEAKS
1. Cover bolts need tightening; gasket broken or
defective
2. Mechanical seal (used on certain models) may be
scratched, due to dirt
3. Inlet head pressure too high. Install a pressure
reducing valve set at 3 psig or less
4. Oil line fitting not tight
CAPACITY TOO LOW
1. Suction lift too high (see page 12, Figure 10)
2. Air leak in suction line
3. Suction line too small (see page 12, Figure 10)
4. Check valve or strainer is obstructed or dirty
5. Mechanical defects - pump badly worn or seal
defective
For additional oil pump information, refer to the oil pump
manufacturer’s product bulletin supplied with the burner.
C35
Rev.304

Figure 32
Gas/Oil Burner Firing Head Cutaway View
Showing Direct Spark Ignition On Oil, Gas Pilot Main Gas Flame Ignition - Using A Common Scanner For Both Fuels
Figure 34
C6 Gas Gun Assembly
28.344 [2811/32] Initial Setting Full Foward
5/32” Diameter Orifice
Pilot Extends Thru Diffuser 0.125 [1/8]
2.250 [21/4] I.D.
7.816 [7 13/16]O.D.
As Shown Fig. 37
1.500 [11/2] Front
Side View
Top View
*NOTE: Blade Setting May Change For
Specific Boiler Models (Consult Factory)
1/2” Blade Setting*
+1/16” Blade Tips After Adj.
Must Be Within 1/16” of
a Flat Plane
-View
Figure 33
C5B Gas Gun Assembly
6.938 [
6
Figure 35
C5B-C6 Gas/Oil Gun Assembly
Side View
*NOTE: Blade Setting May Change For Specific Boiler Models (Consult Factory)
As Shown Fig. 37
Front
View
Top View
Initial Setting 31.875 [317/8] C6
Initial Setting 31.310 [315/16] C5B
7.816 [713/16]O.D. C6 /6.938 [615/16]O.D. C5B
2.250 [21/4] I.D.
Max. Insertion Lock Collar Must Be Set
To Prevent Diff. From Falling Out Forward
1/2” Blade Setting*
1/16” Blade Tips After Adj.
Must be Within 1/16” of A Flat Plane
Mark Pipe With Saw For Full
Forward
Pilot Extends Thru Diffuser 0.125 [
1
/
8
]
5/32” Diameter Orifice
+
-
Gas Inlet
Oil Nozzle
Choke Assembly
Boiler Flange
NOMINAL FAN DIFFUSER OPENINGS: C1- 1/4”, C2 - 3/8”, C3 through C8 - 5/8”
JOB CONDITIONS such as high altitude may require adjustment of diffuser blades to alternate settings. Certain OEM applications may
require settings of diffuser blades or electrodes not listed or shown. Setting of electrodes closer to center of nozzle and or farther forward
may be required.
Scanner Pipe
Gas
Pilot
Initial Setting 28.344 [28
11/32]
5/32” Diameter Orifice
Pilot Extends Thru Diffuser 0.125 [1/8] From Front of Nozzle Adpt. to
Back of Diff 2.000 [2]
1/2” Blade Setting*
+1/16” Blade Tips After Adj.
Must be Within 1/16” of A Flat Plane
2.375 [2 3/8]I.D.
As Shown Fig. 37
Front
Side View
Top View
*NOTE: Blade Setting May
Change For Specific Boiler
Models (Consult Factory) 15/16] O.D.
View
Boiler Flange
Gas Pilot
Scanner
Pipe
Stainless
Steel
Diffuser
Choke
Assembly
Electrode Support
Blast Tube
Ignition Elec-
trode
Air Air
Air
Gas
Bypass
Oil Line
Oil
Supply
Air
1”
C36
Rev.304

C42
Rev.304
TROUbLE ShOOTING SUGGESTIONS
GAS, OIL OR GAS/OIL bURNER
GENERAL
1. Burner Fails to Start
A. Defective On/Off or fuel transfer switch. Replace.
B. Control circuit has an open control contact.
Check limits, low water cutoff, proof of closure
switch and others as applicable.
C. Bad fuse or switch open on in-coming power
source. Correct as required.
D. Motor overloads tripped. Reset and correct
cause for trip out.
E. Flame safeguard control safety switch tripped out.
Reset and determine cause for apparent flame
failure.
F. Loose connections or faulty wiring. Tighten all
terminal screws and consult wiring diagram
furnished with the burner.
G. Frozen oil pump shaft preventing blower motor
operation. Replace oil pump.
H. Flame safeguard control starting circuit blocked
due to flame relay being energized. Possible
defective scanner--replace. Possible defective
amplifier--replace. Scanner actually sighting
flame due to leaking fuel valve--correct
unwanted flame cause. Defective flame
safeguard control--replace.
I. Defective blower motor. Repair or replace.
2. Occasional Lockouts for No Apparent Reason
A. Gas pilot ignition failure. Refer to pilot
adjustment section and readjust to make certain
that ignition is instant and that flame signal
readings are stable and above minimum values.
Use a manometer or 0 to 10” W.C. gas pressure
gauge on pilot test tee to make certain that
pressure is as recommended.
B. Check for proper settings on direct spark oil
ignition electrodes. Make certain that gap is not
too wide and that light-off oil pressure is as
recommended in Section 3.
C. Gas pilot ignition and direct spark oil ignition.
Verify that there are no cracks in the porcelain
and that transformer end and electrode end plug
in connections are tight.
D. Loose or broken wires. Check all wire nut
connections and tighten all terminal screw
connections in panel and elsewhere as
appropriate.
E. With flame safeguard controls that incorporate
the air flow switch in the non-recycling circuit,
ensure that when main flame lights, the air flow
switch is not so critically set as to allow
occasional momentary opening of the air switch
contacts.
F. Occasional low voltage supply. Have local utility
correct. Make certain that the burner control
circuit transformer (if supplied) is correct for the
voltage being supplied.
G. Occasional low gas supply pressure. Have local
utility correct.
H. Air leak in oil suction line or check valve not
holding. Correct as required.
GAS OPERATION
1. Burner Motor Runs, but Pilot Does Not Light
A. Gas supply to burner shut off--make sure all
manual gas supply valves are open. Automatic
high pressure valve at meter such as Sentry
type tripped shut due to high gas pressure--reset
valve and correct cause for trip out.
B. Pilot solenoid valve not opening--listen and feel
for valve actuation. Solenoid valve not being
powered--check electrical circuitry. Replace coil
or entire valve if coil is burned out.
C. Defective gas pilot regulator--replace.
D. Gas pressure too high or too low at pilot orifice.
Check orifice size in gas pilot assembly. Replace
if incorrect. Refer to gas pilot adjustments for
correct settings. Readjust as required.
E. Defective ignition transformer--replace. Incorrect
ignition electrode settings--refer to gas pilot
adjustments for correct settings.
F. Defective flame safeguard control or plug in purge
timing card. Replace as required.
G. Air flow switch not making circuit--check out
electrically and correct pressure adjustment on
switch if required. Defective air flow switch--
replace. Air switch negative pressure sensing
tube out of position--reposition as necessary.
2. Burner Motor Runs and Pilot Lights, but Main Gas
Flame is Not Established
A. Main shut off or test cock closed. Check to make
certain fully open.
B. Pilot flame signal reading too low to pull in flame
safeguard relay. Refer to gas pilot settings
section and readjust as required.
C. Defective automatic main or auxiliary gas shut off
valves. Check electrical circuitry to valves.
Replace valves or correct circuitry as required.
D. Main diaphragm shut off valve opening too slowly.
Adjust bleed on valve.
E. Defective flame safeguard control or plug in
amplifier. Check and replace as required.
F. Butterfly valve set incorrectly on modulating
burner. Readjust as required.
G. Main gas pressure regulator atmospheric vent line
obstructed. Correct.
H. Defective main gas pressure regulator--replace.
Misadjusted main gas pressure regulator--
readjust to meet required operational values.
3. Carbon Monoxide Readings on Gas Firing
A. Flame impingement on cold heat transfer
surfaces caused by excessive firing rate.
Reduce firing rate to correct input volume.
B. Flame impingement on cold combustion chamber
surfaces due to undersized combustion chamber.
Refer to chamber size charts, pages 14 and/or
contact factory for additional information.
C. Incorrect gas/air ratios. Readjust burner to correct
CO2/O2levels, reducing CO formation to appropriate
level. See NOTE on page 25 and page 41, Table 13
for additional information.

4. Gas High Fire Input Cannot Be Achieved
A. Gas company pressure regulator or meter
operating incorrectly, not allowing required gas
pressure at burner train inlet. Have gas company
correct.
B. Gas cock upstream of train inlet not fully open.
Check and correct.
C. Gas line obstructed. Check and correct.
D. Gas train main and/or leak test cocks not fully
open. Check and correct.
E. Gas supply line between gas company regulator
and burner inlet too small. Check supply pressure
at meter, determine pressure drop and increase
line size as required, or raise supply pressure to
compensate for small line. Do not raise pressure
so high that under static (no flow) conditions the
pressure exceeds the maximum allowable
pressure to the gas train components on the burner.
F. Burner gas train components sized too small for
supply pressure. Increase component size as
appropriate.
G. Automatic gas valve not opening fully due to
defective operation. Replace gas valve.
H. Side tee (limiting) orifice (if supplied) too small.
Replace with correct size.
I. On modulating burner, butterfly valve not fully
opened. Readjust.
J. Defective main gas pressure regulator. Replace.
K. Incorrect spring in main gas pressure regulator.
Replace as required.
L. Main gas pressure regulator vent line obstructed.
Check and correct.
M. Normally open vent valve (if supplied) not closing
when automatic gas valves open. Check to see if
valve is fully closed when automatic valves are
open. Replace vent valve, if not closing fully.
OIL OPERATION
1. Burner Motor Runs, but Direct Spark Ignited Oil
Flame is Not Established
A. Defective or incorrect size oil nozzle. Remove and
clean or replace.
B. Low oil pressure. Check with gauge for correct
light-off pressure.
C. Defective oil pump. Replace.
D. Defective oil solenoid valve. Replace.
E. Oil pump coupling loose or defective. Replace or
tighten as required.
F. Low oil pressure switch (if supplied) defective or
incorrectly set. Adjust or replace switch.
G. Ignition transformer defective. Replace.
H. Ignition electrode set incorrectly. Remove electrodes
and reset.
I. Ignition electrodes cracked and grounding out
spark. Replace electrodes.
J. Ignition leadwire defective and grounding spark out.
Replace.
K. Ignition plug in connections at transformer or
electrodes loose. Tighten.
L.. Air flow switch (if provided) not making. Reset
pressure or replace.
M. Defective flame safeguard control or plug in
purge timer card. Replace.
N. Air dampers held in high fire position due to
mechanical binding of linkage. Readjust linkage.
O. Loose wiring connections. Check and tighten all
connections.
2. Oil Flame Ignites, but then Flame Safeguard
Control Locks Out on Safety
A. Flame scanner lens dirty. Remove and clean.
B. Scanner sight tube blocked or dirty. Check and
clean.
C. Flame scanner defective. Replace.
D. Defective oil nozzle causing unstable flame and
scanning problems. Replace oil nozzle.
E. Fuel/air ratios incorrect, resulting in unstable or
smoky flame causing scanner flame sighting
problem. Readjust ratios for clean stable flame.
F. Defective flame safeguard amplifier or control.
Replace as appropriate.
3. Oil Flame Extremely Smoky at Light Off or in Low
Fire Position
A. Defective or incorrect size oil nozzle. Replace.
B. Fuel/air ratio incorrect. Readjust.
C. N.C. oil solenoid valve in oil nozzle return line not
opening. Check electrical circuitry and replace
valve if defective.
D. On two-step pump - N.O. pump mounted solenoid
valve malfunctioning. Replace valve or pump.
4. Light Off Oil Flame Is Established and Proven, but
Burner Will Not Attempt to Go to the High
Fire Position
A. Low/High/Low or Modulating burner high fire
temperature or pressure control could be
defective or not set to call for high fire. Readjust
or replace control.
B. Loose wires or incorrectly wired. Verify wiring and
tighten all connections.
C. Flame safeguard control or high fire panel
switching relay (if supplied) defective. Verify and
correct as required.
D. High fire 3 way solenoid valve defective. Replace.
E. Hydraulic oil cylinder defective. Replace.
F. On two-step pump - N.O. solenoid valve defective
(not closing). Replace pump or valve.
G. Linkage mechanically binding. Readjust linkage.
H. On modulating system - defective modulating
motor. Replace.
5. Low Oil Flame Is Established and Proven, but Flame
Out Occurs in Transition from Low Fire to High Fire
A. On Low/High/Off or Low/High/Low system - N.C.
oil solenoid valve in nozzle return line not closing
(or leaking). Check valve operation and replace
if necessary.
B. On two-step oil pump - N.O. solenoid valve
defective (not closing). Replace valve or pump.
C. Defective or incorrect size oil nozzle. Replace.
D. High fire oil pressure too low. Readjust.
E. Air dampers set too far open at low fire, which
causes flame to blow out in starting to high fire.
Readjust dampers.
F. Oil pump coupling loose or defective. Tighten or
replace.
G. Defective oil pump. Replace.
H. Linkage mechanically binding. Readjust.
I. Make certain the #72 orifice into the N.C. side of
the 3 way valve has not been removed.
J. On modulating systems - fuel/air ratios set
incorrectly, causing flame to blow out when
going to high fire. Readjust linkage.
C43
Rev.304
TROUbLE ShOOTING SUGGESTIONS
GAS, OIL OR GAS/OIL bURNER