Wayne MSR, MSR-DC User Manual

WAYNE COMBUSTION

SYSTEMS

801

GLASGOWAVE.

FORT WAYNE, IN

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ELECTRIC

SHOCK

HAZARD

HIGH VOLTAGES ARE

PRESENT

IN THIS EQUIPMENT,

FOLLOW

THESE RULES TO AVOID ELECTBIC SHOCK.

A

Use

only

a

properly

grounded

circuit. A

ground

fault

interrupter

is recommended.

A Do not spray water

directly on burner.

A Turn

off

power

before servicing.

A

Read the

owner's manual before using.

c

OVERHEATING

HAZARD

SHOULD OVERHEATING

OCCUR:

A Shut

off

the

manual

oil

valve

to the appliance.

A Do not shut off the control

switch to the oumo or blower.

NEVER ATTEMPT

TO USE

GASOLINE AS A FUEL FOR

THIS BURNER, AS

IT

IS MORE COMBUSTIBLE AND

COULD

RESULT IN A SERIOUS EXPLOSION.

MODET MSR

SPECIFIGATIOI{S

FIRING

CAPACITIES MODEL MSR

FOR VOUR

SAFETY

DO NOT STORE OR USE GASOLINE OR
OTHER

FLAMMABLE VAPORS

AND

LIQ-

UIDS

IN

THE

VICINITY

OF THIS OR ANY

OTHER APPLIANCE.

O.5O TO 2.75

GALLONS

PER

HOUR

70,000

To 385,000 BTU/HR TNPUT

FUELS

Use No. 1 or No. 2 Heating

Oil

(ASTM

D-396),

Kerosene, Diesel

& JP8 Jet Fuel.

-

NEVER attempt to

use

gasoline

as a fuel

for

your

burner,

as it

is

more combustible and could result in a seri-

ous explosion.

ELECTRICAL

Power

Supply ..........tt 5V I6OHZ/

1 PH

Motor.....,...

,..........,..3450 RPM,

N.E.M.A. 48 Flange, Manual Reset

Overload Protection

lgnition.......

,.,..,..,..,..10,000V I

23MA secondary, Continuous

Duty-Shielded, Interrupted

Duty Shielded Transformer,

or Solid-State lgnition

System,

DTMENSTONS

(STANDARDI

FUEL PUMPS

HEIGHT.....

..............11%" Suntec or

Danfoss - Single Stage Standard

wlDrH

............. ....tsvj:'

MOUNTTNG

DEPTH......

................6%"

"

Rigid Flange, Adjustable Flange,

or

Base

Mount

INSTALLATION OF

BURNER

INSTALLATION

OF THE BURNER MUST

BE DONE

BY A

QUALIFIED

INSTALLER IN ACCORDANCE WITH REGULATIONS OF THE NATION.

AL FIRE PROTECTION

STANDARD FOR

OIL-BURNING

EOUIPMENT, NFPA NO. 31,

AND IN

COMPLETE

ACCORDANCE WITH ALL LOCAL

CODES AND AUTHORITIES HAVING

JURISDICTION.

A

QUALIFTED INSTALLER

tS THE

PERSON

WHO IS RESPONSIBLE FOR

THE INSTALLATION AND ADJUSTMENT OF

THE

EQUIPMENT

ANQ WHO

lS

LTCENSED

TO TNSTALL

O|L-BURNTNG

EOUIPMENT tN ACCORDANCE

WrTH ALL CODES

AND

ORDINANCES.

WARRANTY

IS

VOIDED

IF

NOT INSTALLED BY

SERVICE

PEHSON.

THESE

INSTRUCTIONS SHOULD

BE AFFIXED TO

THE BUHNER

OR

ADJACENT TO THE HEATING

APPLIANCE.

\

APPROVALS

/ll

me

burner is U.L. listed, for use with

Group

I or

Group

ll

primary

safety controls. State

and localapprovals

are shown

V

on

burner rating label. All burners should be installed in

accordance with National

Fire Protection Association,

and

in

l.*:Mcomplete

accordance

with

all local

codes,

and

authorities having

jurisdiction.

Regulations

of these

authorities

take

'---

precedent

over

general

instructions

provided

in this manual.

GENERAL INFORMATION

Heating Plant - Before installing this burner in a

conversion

installation,

try

to

provide

adequate

space to service the

burner

properly.

The

heating

system

should

be carefully inspected for defects

and cleanliness, so

proper

performance

is

obtained. An oil burner is only a means of supplying heat to the firebox

and

from there the heating system

must

absorb

and circulate the heat. The flue

passages

and

heat

absorbing surfaces

must be clean

to

assure

maximum

heat

transfer

to the furnace or boiler.

Soot and

fly

ash

act as insulators, retarding

the

transfer of heat, All doors, openings,

and

cracks should

be cemented air-tight to

eliminate

air infiltration inlo the heating

plant,

causing heating

losses.

lnspect

smoke

pipe

and

chimney for

elimination

of leaks

and obstructions.

Be

sure of adequate chimney size and

height.

Install a mechanical

draft adjuster,

if needed

same

size

as smoke

pipe (see

column

under draft regulators).

COMBUSTION

CHAMBER

The

purpose

of a combustion chamber

is to maintain a high flame

temperature by

reflecting

the

heat

back into the

flame. A high temperature

assures

greater

combustion etficiency and lower stack losses. An insulating refractory or

a Fiber Fax type

chamber can be used

with this

burner.

lt is important to select and install,

if

necessary, the correct

size chamber

on the

conversion

job

(see

chart).

On the

Flamelock

conversion burners

the

atomized oil burns

just

off

the flamelock. On all oil burners the atomized oil must not touch the sides or bottom of

chamber, or smoke

will

result.

To eliminate the smoke,

excess

air will be required, resulting

in

high stack temperature

and lower combustion effi-

ciency. lnstall

burner

so the face

of air

cone

of burner is

set 1/8"

lo 114" behind the inside

front wall of the

chamber

(see

diagram). Caution

on

installing

Flamelock burners in

stainless

steel chamber should be

taken because

of

the

higher temperature levels

produced

by

high

performance

flame retention burners. The

temperatures may exceed the

temperature ratings of the

stainless

steel chamber, and can result in chamber burn out. Where

you

are

replacing a

standard

burner

with a flame retention burner, take

one

of the following

precautions: (1)

Use

"Wet Pac" Ceramic

Liner

to line the inside

of chamber,

(2)

Adjust

burner

(see

FinalAdjustments Column).

FUEL

UNITS AND OIL

LINES

Conversion

Burners

are

provided

with

single stage

3450

RPM

fuel units

with

the by-pass

plug

removed for single

pipe

installations.

This

is

satisfactory where the fuel supply is on the same level or above

burner

permitting

gravity

flow of

oil.

Never

exceed over 8 PSI

pressure

to

the suction

side

of fuel unit. A

pressure

of

over I

PSI

may

cause

damage

to the shaft seal and

allow it to leak

oil. When it is necessary to lift the

oil to

the burner, a return line should be run

between

fuel unit and oil supply.

(lf

lift exceeds 10 feet, a two-stage fuel unit must be used

with

a return

line).

When

a

two-line

system is used the

by-pass

plug

must

be installed. This

plug

is supplied along

with the burner attached to

fuel unit along with an information

pump

data

sheet

in

a

plastic

bag. When oil

lines are installed, continuous runs of

heavy

wall

copper tubing are recommended. Be

sure that all

connections

are absolutely airtight. Check

all connec-

tions and

joints.

Flared fittings

are

recommended. Do

not

use

compression

fittings.

See

pump

data

sheet for

siz-

ing, lift and length

for tubing

recommendations.

Use an oil filter of adequate size

for

all installations.

Install filters

inside the building

between the

tank

shut off

valve

and

the

burner. For ease of servicing,

locate the

shut-off

valve and

filter near the

burner.

TANKS

AND PIPING

Local

codes and regulations must be

adhered

to

regarding

tank

and burner installation.

WIRING

All wiring must

comply

with

the National Electric Code and local ordinances,

refer

to

diagram supplied

with burner or

controls, making

sure

the

burner and controls

are wired

correctly and that the

line

switch is

properly

fused

to

burner.

AIR

SUPPLY FOR COMBUSTION

Do not install in rooms

with insufficient air to support

combustion. Occasionally

it is necessary

to install windows

or

cut holes in a

door to these rooms to obtain sufficient air and to

prevent

less than

atmospheric air

pressure

in the

room. lf there is a lack of combustion

air in

the

room,

the

burner flame will be

yellow

and formation of soot will

occur

in the heating unit. In

buildings of conventional frame,

brick

or stone

construction

without utility

rooms,

basement win-

dows, or

stair

doors,

infiltration

is

normally

adequate

to

provide

air for

combustion

and for operation of the

barom'et-

ric draft control. For installation

in

an enclosed

utility room

without an outside

wall, a fresh air opening to the outside

with a free cross

section area of 2O square

inches

per

each

gallon per

hour firing

is recommended.

For each

1,000

feet

above sea level, increase the fresh

air opening by

at

least four

(4)

per

cent.

The room should

be isolated

fiom

any area served by

exhaust

fans. Do not

install an exhaust

fan in this

room.

2

CIIIMNEY

Follow

the recommendations of the heating

unit

manufacturer. lt must be

properly

designed and of adequate size

and

should be

above the surrounding

objects, tile-lined,

with no

obstructions

and be in

good

state

of

repair.

The smoke

pipe

should

set

flush

with

the

inside of the tile and cemented in

place.

All

cleanout

doors

should

be

sealed.

DRAFT REGULATIONS

The

use of a draft

regulator is recommended

and

should

preferably

be mounted

in the smoke

pipe.

Use a

draft

gauge

to adjust

to

proper

opening.

When

the burner

air supply is

properly

adjusted,

the

combustion chamber

draft

will

be

approximately

-.

01 to -.

02

WC

and the stack

draft will be

-.02

to

-.04

WC, The

larger

the

installation, the

greater

the

draft

will

be

required at the stack to obtain the

-.01, to

-.02

WC

at the combustion

chamber.

hrozzLEs

Use

the

proper

size, type and spray

pattern

that

heater manufacturers

recommend; in some cases of

upgrading or

conversion

installations, the

use of an 80(

Hollow

or

Solid

Nozzle

are

the best to start

with.

STARTING

PROCEDURE

STARTING

BURNER

Be sure

main switch is in

"off"

position

and

be sure

thermostat is substantially

above

room temperature,

the oil tank

is filled,

all valves are

open and controls set

for operation. Adjust

air supply on

burner by loosening

the locking

screw

on outer

air band,

and open

partially.

Open

the inspection door

and turn on switch.

Prime

pump

according to the

pump

manufacturer's

recommendations

and check

pressure.

lf safety lockout

occurs reset

after 1

or 2 minutes

(cau-

tion). Do not

run fuel

unit dry for more

than 5 minutes.

When

fire

is established

make a temporary

air adjustment

lor

a clean

combustion

flame, reduce air supply until

flame tips appear

slightly smoky,

then readjust so flame tips are

clean looking. Leave inspection

door open

until chamber

is

dry.

When normal

temperatures

are

reached, close

inspection door

and adjust

draft regulator,

see

column under

"DRAFT

REGULATIONS".

FTNAL

ADJUSTMENTS

At this

point

a final adjustment should be

used

by

the

use of

a COMBUSTION

TEST KlT. After

operating 10

minutes

to

warm up unit, a smoke tester should be used

to take

a smoke

reading.

We

are

wanting no

greater

than a #1;

(Shell

Bacharach

Scale). And

less than

a #1 smoke

is

desired.

Sometimes a

new heating unit

requires mqre time than this

to

burn clean due to the oil film

on the new heater unit

surfaces.

Recheck draft and

take a COz reading over the fire

and

in the stack. lf a larger

differential between COz

readings is noted, air

leakage

is the

most common cause

(see

:olumn under HEATING

PLANT).

CO, readings

must all be

taken ahead of draft control.

The

COz measured in the

stack

should be at least

9o/"

tor oil rates 1.00

G. P

H. or below, and

at least 10%

for oil rates

over

1.00 G.P.H.

Unit

should be started and

stopped

several times to assure

good

operation.

Open inspection door,

turn off oil valve and

check

out safety

timing

of combustion control. Check operation

of limit controls

and thermostat. Check for oil leaks.

Note: All installations should

be reinspected

after 1 or 2

weeks

of normal

operation.

FTNA[-

CHECKS

Be

sure air band and draft control adjustments are locked,

and the

controls

on heating

unit are adjusted in accordance

with the Heater

and

Control

Manufacturer's Instruction Sheets. Use

efficiency chart

(page

4)

to

finalize set-up.

MAINTENANCE
OILfNG MOTOR - By

proper

oiling

twice

ayeat,

the motor

life

will be

increased; only

a few

drops

of a non-detergent

type of

oil at both

motor holes is needed.

FILTER - The oil filter cartridge

should be replaced

once a

year

so the fuel oil

will not become contaminated

and

plug

up fuel

pump

and nozzle of oil burner.

NOZZLE - The nozzle

should be changed at least

once a

year

before

the start-up

of the heating

season. Replace

with

proper

nozzle.

Handle

Nozzles

by

hex only. Oil from the

fingers

on the

face or filter

of nozzle may

adversely

affect spray

characteristics,

COMPONENTS

-

lf

for

any reason

any

of the burner

pans

have to

be replaced,

always

use

parts

recommended

by

the

manufacturer. Specify

part

numbers,

and

description,

when

ordering.

(lN

ALL COMMUNICATIONS

STATE

BURNER

MODEL,

SERTAL NUMBER AND

SPECtFICATION

NUMBER).

ELECTRODE

SETTINGS - This is very important

for reliable

ignition

of the

oil; check these once a

year

in accor-

dance with

the

instructions

provided

in this manual.

FAN & BLOWER

HOUSING

-

This must be kept clean, free of

dirt and lint.

Open

transformer

to check

fan

blades for

above.

Be

sure

the electric

power

is off on

burner

when

transformer

is opened

for the

inspection.

\

/r)

lttl

E'

-

w[M

3

d

}g!U[LE

EFFICIENCY

GHART

FOR NO.

2 FUEI

OIL

NET

STACK TEMPERATURE

(DEGREES

F")

30q'

350"

400" 450'

500" 550"

600"

650" 700'

750'

800"

850'

900"

87% 861l

85Y^ 84]l

83]l

82 81 79"/q

7834

77% 76% 75% 74%

87%

86% 85

84

83

813/4 843/4

79Y4 78y, 77%

76 75 73%

87% 86

84"/o

82"/o

82sA

81y, 8OY4 79

78

76%

75i4

74% 73

87

853/4

B4'A

B3t(

82tt

81%

80 7B%

7714 76% 75%

74 72y,

86"/q

85]l

B4/4 83% 82

80%

79b

7By,

77 75%

7416 73'A

71%

86]l

85Y4

B4 83%

811l

801l 79

77% 76%

75%

7331

7231

71

86% 85

8331 82N

81y, 79"/o 7BY" 77%

753/4

74% 73

71%

70%

86

84%

83%

82 80%

79Y4

78 76%

75% 733/o

72Y4 7031

6914

85%

84],l

B3 81% 80%

78/o

77Y4

7531

74%

73 71t{

70 68tt

Bs%

84

B2:A

B1

791t 7B

76rt 75

73% 72

7otn

69 67%

85

83v,

82

BO1A 78% 77Y4 753/4

74/4

723/4 7'l

69b 6B 66Y4

B4TA

B3

81/,

79% 78 761t

75

73% 71s/q

7A

6BY4 66%

65

84

82%

803/o 79

77Y4 75%

74 72Y4

7034

68%

67 65]u 63rt

831l

813/q 80

78Y4

76% 74%

73

71Y^ 691l

6714 651l

633/4

62

83

81

79% 77%

75% 733/o

71% 70

6B

66

64 62

60

82v,

80% 7gti 761l

74tt 72%

70rt

68]A

6616

64y, 62% 60 5B

81'A

79% 77Y4

75% 73Y4

71

69

67

64% 62v,

60Y4

573/4

55%

80%

78%

76Y4 74

713/q

6914

67Y4

65

62% 601l

57s/4

5514

53

79"/o 77Y4

75

72% 70

67%

65/4

6231 6OY4

5711

55%

52tA 50

78%.

76

73t6 71

68

65t4 63

601l

57% 54%

51% 49 461l

77Y4

74tt

713/a

69 6531

63

60

57

54

51 48

4514

42:A

75%

72%

69

66U

63

60

56%

53ll 501l 47

4316 4OY4

36%

73%

69% 66%

6231 5gY4

55"/c

52

481l 45

41% 37%, 334/q

30

ATTAC}IING

AIR TUBE

COMBINATIONS FOR

CHASSIS

PLAN

ONLY

When

the

Oil

Burner

Chassis and

the Air

Tube combination

are

packed

separate-

ly,

the Burner must be assembled

as follows:

1 - Install the

Air Tube

Assembly

to the

Burner Chassis

as shown. This can

be

done

by setting the

Burner

Chassis on its back and

placing

the assembled

Air Tube

on the

Chassis.

(IMPOHTANT:

Make sure

the Oil Drip hole in

Air

cone

(see

Fig. 1)

is

at

the

six o'clock

position.)

Secure air

tube

to chassis

with

3 HEX HEAD

SCREWS,

2 - lnstall

proper

nozzle

in Drawer

Assembly. Loosen the Transformer

retain-

er Screws

and swing

open

to inserl

the Drawer Assembly

(See

Fig. 2.) into

the air tube to

position

nozzle.

Once

installed

and adapter

fitting

is in

posi-

tion in Burner

Chassis slot and

slide

place

hole, adjust

gun

assembly,

either

back or foruard to

position

nozzle from head. For

correct

positioning

(See

Fig. 3).

Secure

the slide

plate

by tightening

screw at side

of

housing.

Secure the

drawer assembly with the

locknut

provided.

Attach

flared nut of

Oil Line Assembly,

(Copper

Oil

Line) to

the end of this adapter fitting

as

shown.
Install

arrow

decal

as

shown

so

position

of Drawer

Assembly,

is

always

known,

(See

Fig. 4)

Recheck

lor nozzle

centering before burner is installed

(See

Fig. 1). Make

sure

electrode

tips

clear retention

head.

.\

/al

u

tffi

INSERT "SR"

SERIES

GUN

SETTING

GAUGE

(AS

SHOWN

BELOW)

TO

CHECK

NOZZLE

POSITTON AND ELECTRODE

SETTING.

FLAMELOCK

CONE

"SR"

SERIES

GUN

SETTING

GAUGE

ARROW

DECAL

SLIDE

PLATE

SCREW

FIG.3

5/16"

BETWEEN

CENTER

OF ELECTRODE

AND

CENTER

OF NOZZLE

1/8"

FROM
END OF
NOZZLE

TO

TIP

OF

ELECTRODES

5

FIG.

1

(TOP

V|EW

OF BURNER)