TM 5-3895-374-24-2 Burner Start Up Sequence Instructions 1. Prior to burner start up - contact the  local  gas  company to determine if any correction factors have to be applied to  their  indicated  meter  flow  rates.    This  information  is important as relates to achieving specific heat exchanger BTU/HR    inputs.        Refer    to    page    36    for    additional combustion  analysis  information  and  to  page  6  for  firing rate information. 2. Refer   to   the   gas   piping   diagram   furnished   with   the burner.  Check gas piping, controls and valves for leaks and compliance with codes. 3. Check    all    linkages.        If    the    system    is    a    packaged burner/heat exchanger system, the linkage was probably set when the system was test fired at the heat exchanger manufacturer’s  factory.    It  should,  however,  be  checked to  ensure  that   it   was   not   damaged   in   shipment.      On conversion  units  (where  the  burner  and  heat  exchanger are mated in the field), the linkage will have to be set to suit the particular operating conditions. 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. Remove the pilot assembly and check for proper settings of the spark gap, tightness of electrode in its bracket and firm connections of the electrode cable.  (See Page 35.) 6. Close  main,  checking  and  pilot  gas  cocks.    Install  one gas  pressure  gauge  to  read  burner  firing  head  pressure (use a 0-10” W.C.  gauge or a manometer).  See Section 3  for  pressure  sensing  locations.    Install  a  second  gas pressure gauge to read gas supply pressure between the main  gas  cock  and  the  inlet  to  the  main  gas  pressure regulator (use a 0-35” W.C. gauge or as appropriate).  If there  is  no  tapping  in  this  location,  install  a  tee  at  the point where the pilot gas supply is connected to the main gas  line.    Slowly  open  the  main  gas  cock  in  order  to determine  that  the  incoming  gas  pressure  is  within  the specified   limits   of   the   main   and   pilot   gas   pressure regulators,   automatic   fuel   valves   and   gas   pressure switches.    Many  systems  are  rated  for  a  maximum  gas supply of pressure of 14” W.C.  If pressure exceeds this value,  consult  the  first  page  of  the  Burner  Specification Sheet  and/or  gas  component  product  bulletins  supplied with  the  burner  to  ensure  that  the  supplied  system  can operate properly at such elevated supply pressure. 7. Disconnect  pilot  line  at  inlet  to  the  pilot  gas  pressure regulator and purge air from the pilot gas line.  Purging of gas lines must be done in accordance with NFPA 54 of the  National  Fire  Protection  Association's  National  Fuel Gas  Code.    After  the  air  is  purged  from  the  gas  supply system, close the pilot cock and reconnect the pilot line. Leave the pilot cock closed. 8. Install required system measuring devices: a) appropriate flame  signal  meter  to  the  flame  safeguard  control;  b) manometer  (or  0-10”  W.C.  gauge)  in  the  pilot  test  tee port; c) stack thermometer and CO2 or O2 sample line to the  breaching;  and  d)  draft  gauge  to  the  combustion chamber test point. 9. It is strongly recommended that  an  automatic  gas  valve “bubble  leak  test”  be  performed  in  accordance  with  the gas   valve   manufacturer's   instructions   on   every   new installation and periodically afterwards in order to ensure that     the     valve     is     functioning     according     to     the manufacturer’s specifications. according to the manufacturer's specifications.  It is also suggested  that  the  test  be  conducted  during  a  normal prepurge  burner  operation.    This  test   will   reveal   any problems  that  relate  to  incorrect  wiring  of  the  automatic gas valve that could cause premature energization of the valve. 10. Set  the  air  dampers  approximately  1/4”  open,  and  with both pilot and leak test gas cocks closed, open the main gas   cock   (to   allow   the   low   gas   pressure   switch,   if supplied, to make its circuit).  With the 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 rotation is correct. 11. Restart  the  burner.    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 lock-out mode,  requiring  manual  reset  of  the  flame  safeguard control to restart the burner. 12. Wait  three  minutes,  reset  the  flame  safeguard  control safety  switch  (restarting  the  burner)  and  open  the  pilot gas  cock.    When  the  blower  prepurge  period  ends  and the  burner  is  energized  -  if  the  flame  safeguard  control has  a  time  “stop/run”  switch  -  stop  the  timer  while  the pilot is on and make adjustments as required.  See page 34   for   pilot   ignition   adjustments.      If   the   burner   has automatic air damper operation (dampers  moved  by  the automatic gas valve or modulating motor) and the Flame Safeguard   control   does   not   have   a   timer   “stop/run” switch, it will be necessary to keep the air dampers in the pilot   light   off   (low   air   flow)   position   by   temporarily electrically   disconnecting   the   motorized   gas   valve   or modulating motor to complete pilot adjustments.  Recycle the burner  several  times  to  make  certain  pilot  operation is reliable. 13. With pilot adjustments completed, reset the timer switch to  the  “Run”  position,  which  will  allow  the  sequence  to proceed  to  the  automatic  gas  valve  energizing  position. If  the  motorized  gas  valve  or  modulating  motor  wires have    been    disconnected,    shut    the    burner    off    and reconnect   electrically   to   allow   normal   automatic   air damper operation. 14. When  the  main  automatic  gas  valve  begins  to  open, slowly  open  the  checking  gas  cock  to  light  off  the  main flame.  The main flame should light immediately.  If not, it may be necessary to eliminate air from the main gas line and/or adjust main gas pressure regulator flow rates. 15. Adjust   the   burner   as   necessary   to   provide   smooth ignition  of  the  main  flame.    If  the  flame  signal  drops significantly  when  the  main  automatic  gas  valve  opens, slightly increase the pilot gas pressure to attain a stable flame signal value. 16. For   On/Off   burners   -   adjust   the   main   gas   pressure regulator  to  achieve  the  proper  main  flame  gas  input. Set  and  lock  the  air  dampers  to  provide  8  1/2  to  10% CO2  (Carbon  Dioxide)  and  0%  CO  (Carbon  Monoxide). Make  certain  the  gas  pilot  operates  reliably  at  the  final fuel/air settings. (page 3 - 976)