North American 4987 Zephyr ™ Burners Single Burner Start-up Instructions
Supplement 4987
Burner Air Pressure Tap
Combustion Chamber Pressure Tap
Q
R
B
Air to Oven
Blower and Tap
A S
Fan
Air from Oven
Vent to a safe location
A – 4987 Zephyr™ B – Flame Protection Tube E – Relief Valve (if required) F G – 8697 Metering Orifice H – Manual Shutoff J – Leak Test Valve
L
E
– Adjustable Port Valve and Actuator
K
M
P
H
Optional location
F
H G
J
J
K – Automatic Safety Shutoff Valve #2 L – Vent Valve (for IRI) M – Automatic Safety Shutoff Valve #1 P – Main Gas Pressure Regulator Q – Burner Air Flow ( P) Pressure Switch (Purge) R – Combustion Air Switch S – Valve and Actuator on Burner
SINGLE BURNER START-UP INSTRUCTIONS
1. Set all safety limit switches to the correct settings (combustion air pressure, purge, low and high gas pressure, high temperature limit, etc.). Shut all manual gas valves. 2. Ensure that system is ready for operation. Start the system fan(s). 3. With the system fan(s) in operation and the burner blower off, mea- sure and record system pressure (or suction) from the burner fuel pressure tap. 4. Jog the burner blower and verify correct impeller rotation (see Fig- ure 3). 5. With the manual gas valve(s) still closed, and the system fan(s) and burner blower running, measure and record the differential pressure between the air and fuel pressure taps located on the burner. For Zephyrs with manual air control , set the differential pressure to 1"wc using the dial indicator and lock down knob. For Zephyrs with linked air and fuel control , the differential pressure will change depending on the control actuator position, combustion chamber pressure and burner fan selection. Min and max combustion air flow rates are provided in Table 2 (page 3). Verify specific burner control options using Dimensions 4987 and the part number that is indicated on the burner label. 6. Stroke the fuel control actuator. For Zephyrs having the control actuator on the burner itself , the valve position can be viewed at the indicator pin on the coupling located between the control motor and burner. The burner is marked "C" for closed and "O" for open, and rotates 90° clcokwise (cw) from "C" to "O" (see Figure 3). For Zephyrs having a remote adjustable port valve and control actuator , adjust the gas valve 1/8 open at low fire, and full open at high fire.
7. Open the manual shutoff valves. For systems having low-fire/ bypass fuel supply components , remove the cap from the limiting orifice valve and turn the adjusting screw cw until it is completely closed. Then turn the screw three full turns counterclockwise (ccw). 8. Initially set the main gas regulator. Remove regulator cap and ad- justment plug (both turn ccw to remove). Confirm that the regulator spring is in the appropriate range of 4 to 8"wc. Replace spring and plug and turn plug cw to mid range of travel, and replace cap. 9. Energize the flame supervisory system. If all of the limit switches are satisfied, the purge cycle will start. When the purge is complete, the burner will begin a trial for ignition. 10. The trial-for-ignition period can vary depending on the supervisory equipment and options being used. Several attempts (resets) may have to occur for the first lighting in order to evacuate air from the fuel line. 11. When flame detection occurs, the system will release to control. With the burner firing, manually set the system controller to low fire. For systems without low-fire/bypass fuel supply components , mea- sure the fuel pressure at the discharge of the main gas regulator, and adjust to 7"wc. Remove cap and turn the regulator adjustment plug cw to increase and ccw to decrease the discharge pressure. For systems with low-fire/ bypass fuel supply components , adjust low fire at the limiting orifice valve. Turn the adjusting screw on the valve ccw to increase or cw to decrease fuel flow.
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