TM 5-3895-374-24-2 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  y,” and  set  forward  to  correspond  with  the  nozzle  spray angle.  Do not set electrodes so that oil can impinge on them.  See page 32 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 pages  34  and  35  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, CO2 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 l 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. 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 ¼” 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,  causing  the  ignition  timing sequence to stop while air and gas pressure adjustments are being made.  See pages 34 and 35 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, nor 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  and  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. If  the  burner  is  direct  spark  ignited,  either  remove  the flame    scanner    from    its    sight    pipe    or    electrically disconnect   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. 14. 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. 15. 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. (page 3 - 979)