C2100AEO-01-2

REVISED 11-24-99

Oil Burner Installation

and Operation Instructions
ALL C2100A SERIES DRYERS

CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Compressor assembly . . . . . . . . . . . . . . . . . . . .4
Air manifold assembly . . . . . . . . . . . . . . . . . . . . .4
Oil pump assembly . . . . . . . . . . . . . . . . . . . . . . .4
Burner test fire . . . . . . . . . . . . . . . . . . . . . . . . . .4
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . .9
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Burner literature . . . . . . . . . . . . . . . . . . . . . . . . .61

Division of ffi Corporation

5900 Elmwood Ave. • Indianapolis, IN 46203
© 1999, 1998 ffi Corporation Printed in USA
Specifications

Oil Specifications

Orifice Air Pump Burner

Diameter Pressure Pressure Pressure oil flow million oil flow
Model (inches) (psi) (psi) (psi) (gal/hr) btu/hr (liter/hr) Mjoules
minimum 8.5 2.0 0.3 7.6 295
24" 0.039 45 100 maximum 25.0 18.0 2.5 68.1 2,659

minimum 8.5 2.0 0.3 7.6 295

28" 0.043 45 100 maximum 28.0 23.0 3.2 87.1 3,397

minimum 10.5 2.0 0.3 7.6 295

36" 0.055 50 100 maximum 34.0 33.0 4.6 124.9 4,874

minimum 10.5 2.0 0.3 7.6 295

39" 0.073 50 100 maximum 50.0 53.5 7.5 202.5 7,902

Burner
• Fuel - #2 oil
• High pressure air atomizing nozzle, 11 cfm @ 40 psi
• Combustion air from air stream

Oil Pump Assy 50 hz 60 hz

Motor
hp 0.5 0.5
rpm 1450 1750
frame 56C 56C
Pump
capacity 108 gph / 409 lph 130 gph / 492 lph
pressure 100 psi / 6.9 bar 100 psi / 6.9 bar

Single Burner Single Burner Double Burner Double Burner

Compressor Assy 50 hz 60 hz 50 hz 60 hz
Motor
hp 5 5 7.5 7.5
rpm 1450 1750 2900 3500
frame 184T 184T 213T 213T
Compressor
capacity 17.3 cfm / .490 m3/m 17.3 cfm / .490 m3/m 26.8 cfm / .759 m3/m 26 cfm / .736 m3/m
pressure 75 psi / 5.17bar 75 psi / 5.17bar 75 psi / 5.17bar 75 psi / 5.17bar
oil 41 oz / 1212 ml 41 oz / 1212 ml 41 oz / 1212 ml 41 oz / 1212 ml
rpm 1040 1040 1611 1555
flywheel sheave 13.5 pd 13.5 pd 13.5 pd 13.5 pd
motor sheave 10.0 pd 8.0 pd 7.5 pd 6.0 pd
Belt A70 A70 A70 A70

3
Oil Burner Installation and
Operation Instructions
Compressor Assembly
• Locate the compressor in a clean
operating area away from the dryer. Locate
inside a shelter when possible.
• Fill compressor with oil supplied before
starting. See operators manual for compres-
sor.
• Do NOT install a shutoff valve on the com-
pressor inlet, outlet or line to the manifold.
• Check for correct rotation of compressor on
startup.
Air Manifold Assembly
• Mount manifold assy to dryer per attached
drawings. Mount manifold with condensate
drain pointing down.
• Connect manifold outlet to burner with
1/2 inch hose supplied.
• Connect manifold to compressor using a
1/2 inch hose. 50 feet have been supplied
• Do NOT install a shutoff valve on the com-
pressor inlet or outlet or lines to the tank.
Oil Pump Assembly
• Install the oil pump assy to the LH front
body supports as shown in attached drawing.
• Connect the pump outlet to the oil manifold.
• Connect the oil manifold to the burner
plumbing assy using 1/4 inch hose supplied.
• Connect a suction line from the tank to the
pump. Line must be adequately sized so that
inlet suction does not exceed 17" hg.
Minimum size is 1/2 inch diameter.
• Connect a return line from the pump to the
tank. Use a minimum of 3/8 inch diameter
line.
• Check for correct rotation on startup. CCW
as view from shaft end of pump or fan end of
motor.
Burner Test Fire
1. Check rotation of compressor by bumping the
pump/compressor switch. Compressor should
rotate CW as viewed from the shaft end of com-
pressor.
2. Check rotation of pump. Pump should run
CCW as view from the shaft end of pump or fan
end of motor.
3. Open the suction and return line valves going
4
to the oil tank. With compressor circuit breaker
off, turn pump switch ON and check for pressure
on outlet gauge. Pressure should read 100 psi.
Adjust pump pressure as required. Check pres-
sure on pump inlet. Inlet pressure should be less
than 17 inches of Hg.
4. Turn on the compressor circuit breaker and
turn pump switch ON. Compressor should begin
building pressure in tank up to 45-50 psi. This
may take 10-15 seconds. Adjust relief valve on
air manifold as required to achieve the 45-50 psi.
Pressure must be in a range between 35 and 60
psi in order to fire the burner.
5. With the high fire valve OFF, turn the burner
switch to the ON position. Following a 30 second
purge period, the burner should attempt to ignite
for 4 seconds and then lockout. The red lockout
light will come on. The dryer will shut down after
a 2-3 minutes unless the flame control is reset or
the burner switch is turned OFF. The dryer shut-
down time can be adjusted by resetting the 3TR
timer located in the ASC box behind the control
front panel.
6. Reset the flame controller by pressing the red
lockout switch. The dryer must be powered, the
pump/compressor switch ON and the burner
switch ON in order to reset the flame control.
When the flame controller is reset (red lockout
light off), it will begin a 30 second purge period
and then try to reignite unless the burner switch is
turned OFF. Turn the burner switch off at this
time.
7. Turn the high fire valve approximately 1/3 on
and the low fire valve approximately 1/3 on. With
pump/compressor and fan motors on, turn the
burner switch to ON. Burner should light immedi-
ately following a 30 second purge period. The
amber light on the burner switch will indicate that
the flame has been proven. Check that the oil
pressure on the burner is in the correct range.
8. Observe fire through the hole in the dryer
access door. Check the quality of the flame
through the normal operating range of pressures
by using the high fire valve to change firing rates.
Typically, no atomizing air adjustment is needed
over the full range of firing rates. The lowest fire
is achieved when fire color begins to turns from
bright orange to purple or blue. The highest firing
rate is achieved with the high fire valve wide
open. If the fire becomes dark or smoky at maxi-
mum rate, reduce the burner valve opening slight-
ly. See chart for suggested maxmum and mini-
mum firing rates.

9. Check the high/low operation of the thermostat.

The burner pressure should cycle between a high
pressure and a low pressure on the burner
gauge. The high and the low pressures should
stay within the suggested operating pressure
range of the burner. See chart.

10. Turn the burner high pressure valve off. The

burner should lockout in 1-2 seconds and the
dryer should shut down in 2-3 minutes. Reset
burner control board.

opumpassy.tif

Fig. 1 Oil pump assembly

obplumbassy.tif

Fig. 2 Burner oil plumbing assembly

5
 contpanel.tif

Fig. 3 Control panel

airmanassy.tif
Fig. 4 Air manifold assembly

6
 compassy.tif

Fig. 5 Compressor assembly

7
 aoburnersc.tif

Fig. 6 Air / oil burner schematic

8
 4b0484a.tif

Fig. 7 Power circuit - C21AE, 1 Y-D 1 oil burner, page 1 of 6.

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 4b0484b.tif

Fig. 7 Power circuit - C21AE, 1 Y-D 1 oil burner, page 2 of 6.

10
 4b0484c.tif

Fig. 7 Power circuit - C21AE, 1 Y-D 1 oil burner, page 3 of 6.

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 4b0484d.tif

Fig. 7 Power circuit - C21AE, 1 Y-D 1 oil burner, page 4 of 6.

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 4b0484e.tif

Fig. 7 Power circuit - C21AE, 1 Y-D 1 oil burner, page 5 of 6.

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 4b0484f.tif

Fig. 7 Power circuit - C21AE, 1 Y-D 1 oil burner, page 6 of 6.

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 4b0485a.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 1 of 8.

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 4b0485b.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 2 of 8.

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 4b0485c.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 3 of 8.

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 4b0485d.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 4 of 8.

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 4b0485e.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 5 of 8.

19
 4b0485f.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 6 of 8.

20
 4b0485g.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 7 of 8.

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 4b0485h.tif

Fig. 8 Power circuit - C21AE, 2 Y-D 2 oil burner, page 8 of 8.

22
 4d0246a.tif

4d0246b.tif

Fig. 9 Layout assembly, C2120AE, single burner.

23
 4d0252a.tif

4d0252b.tif

Fig. 10 Layout assembly, C2120AE, dual burner.

24
 4d0247a.tif

Fig. 11 Fuel oil pkg., OBP1, C2125AE, page 1 of 2.

25
 4d0247b.tif

Fig. 11 Fuel oil pkg., OBP1, C2125AE, page 2 of 2.

26
 4d0253a.tif

Fig. 12 Fuel oil pkg., OBP2, C2125AE, page 1 of 2.

27
 4d0253b.tif

Fig. 12 Fuel oil pkg., OBP2, C2125AE, page 2 of 2.

28
 4d0251a.tif

Fig. 13 Layout assembly, C2140 & 30AE, single burner, page 1 of 2.

29
 4d0251b.tif

Fig. 13 Layout assembly, C2140 & 30AE, single burner, page 2 of 2.

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 4d0250a.tif

Fig. 14 Layout assembly, C2140 & 30AE, dual burners, page 1 of 3.

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 4d0250b.tif

Fig. 14 Layout assembly, C2140 & 30AE, dual burners, page 2 of 3.

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 4d0250b.tif

Fig. 14 Layout assembly, C2140 & 30AE, dual burners, page 3 of 3.

33
 3c0817.tif

Fig. 15 Manifold assembly - air compressor, (single / dual burner).

34
 3d0516a.tif

3d0516b.tif

Fig. 16 Compressor assembly - air, fuel oil burner.

35
 390569a.tif

3d0569b.tif

Fig. 17 Pump assembly - fuel oil, 50HZ & 60HZ applications.

36
 3c0816b.tif

3c0816a.tif

Fig. 18 Manifold assembly - fuel oil, (single / dual burners).

37
 3c0812.tif

Fig. 19 Plumbing assembly - burner, (fuel oil burners).

38
 3d0538.tif

Fig. 20 Fuel oil, nozzle/cone assy, 28”, 36” & 39” (fuel oil burners).
39
 4c0342.tif

Fig. 21 Honeywell burner control assembly.

40
 4c0366a.tif

Fig. 22 Power chassis, C2120AE, 25AE, 380 / 415, 1 Y-Delta 1 oil burner, page 1 of 2.

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 4c0366b.tif

Fig. 22 Power chassis, C2120AE, 25AE, 380 / 415, 1 Y-Delta 1 oil burner, page 2 of 2.

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 4c0364a.tif

Fig. 23 Power chassis, C2130AE, 40AE, 380 / 415, 2 Y-Delta 2 oil burner, page 1 of 2.

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 4c0364b.tif

Fig. 23 Power chassis, C2130AE, 40AE, 380 / 415, 2 Y-Delta 2 oil burner, page 2 of 2.

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 4d0249a.tif

Fig. 24 ASC Control panel, C21AE, page 1 of 3.

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 4d0249b.tif

Fig. 24 ASC Control panel, C21AE, page 2 of 3.

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 4d0249c.tif

Fig. 24 ASC Control panel, C21AE, page 3 of 3.

47
 3c0815a.tif

Fig. 25 Burner box assembly, fuel oil, page 1 of 2.

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 3c0815b.tif

Fig. 25 Burner box assembly, fuel oil, page 2 of 2.

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 3d0580a.tif

Fig. 26 Fan-heater assembly, 24”, 10hp, fuel oil, page 1 of 3.

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 3d0580b.tif

Fig. 26 Fan-heater assembly, 24”, 10hp, fuel oil, page 2 of 3.

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 3d0580c.tif

Fig. 26 Fan-heater assembly, 24”, 10hp, fuel oil, page 3 of 3.

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 3d0577a.tif

Fig. 27 Heater assembly, 28”, fuel oil, page 1 of 3.

53
 3d0577b.tif

Fig. 27 Heater assembly, 28”, fuel oil, page 2 of 3.

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 3d0577c.tif

Fig. 27 Heater assembly, 28”, fuel oil, page 3 of 3.

55
 3d0576a.tif

Fig. 28 Heater assembly, 36”, fuel oil, page 1 of 3.

56
 3d0576b.tif

Fig. 28 Heater assembly, 36”, fuel oil, page 2 of 3.

57
 3d0576c.tif

Fig. 28 Heater assembly, 36”, fuel oil, page 3 of 3.

58
 3d0575a.tif

Fig. 29 Heater assembly, 39”, fuel oil, page 1 of 2.

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 3d0575b.tif

Fig. 29 Heater assembly, 39”, fuel oil, page 2 of 2.

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 PART NO. 006-1388-5

61
Division of ffi Corporation
5900 Elmwood Ave. • Indianapolis, IN 46203
© 1999,1998 ffi Corporation Printed in USA