elco 6.170 L-E, 6.240 L-E, 6.300 L-E, 7.350 L-E, 7.450 L-E Operation Manual

Operation Manual

for the authorized specialist

Oil Burner
EK 6../7../8../9.. L-E

03/2005 102.880.2006

2

Inhalt

Overview Contents ...........................................................................................................2

Overview Important Information Warranty Product Description .......................................3

Technical Data .................................................................................................4

Dimensioned Drawings ....................................................................................9

Operation Start-up Mode Oil Operating Mode General Safety Functions .......................12

Fuel-air Compound Control Hydraulic Diagram .............................................13

Hydraulic Diagram L-E / GL-E Burner EK 6 - EK 9 ........................................14

Operation Hydraulic Valves and Instruments Group .......................................................15

Start-up Burner Head Settings .....................................................................................16

Installation Mounting to Boiler Electrical Connection Presetting ......................................19

Installation Boiler lining for Burner L-R/E .........................................................................20

Oil Connection Oil Pressure Control (Feed) ...................................................21

Start-up Return Nozzle Rod Type RDN Burner Type EK 6 .........................................22

Start-up Nozzle Selection, Type W2-50° ........................................................... ...... ....23

Start-up Return Nozzle Rod RDG 1250 Burner EK 7... - EK 9... .................................24

Nozzle selection „Sonic“ ..................... ..... ...... ....................................... ...... ....25

Checking Procedure .......................................................................................26

Adjusting Instructions Elektronic Burner Control with Electronic Compound Controller ....................27

Flame Detecting System Type FLW 05 .........................................................28

Servomotor Type SAD 15.0 ...........................................................................29

Electrical Actuator STM 40 .............................................................................30

Starting the BCS, Etamatic, VMS/FMS Electronic Compound Controller .....31

Adjusting Instructions Oil Pressure Switch (Option) Air Pressure Switch .........................................32

Operation Automatic Furnace Controller LAL... / LOK... Regulator KS 92 ....................33

Adjusting Instructions Flame Monitor Sensor Current Measurement ...............................................34

Adjustment Fan Impeller ...................................................................................................35

Servicing Instructions Burner Maintenance .......................................................................................36

Exhaust Gas Test ...........................................................................................37

Trouble Shooting Instruction s ......................................................... ..... ...... ....38

Operating Trouble ............................................... ..... ......................................40

System Diagram .............................................................................................41

Overview

Contents

3

Overview
Important Information

Warranty
Product Description

Important information

The burners of type EK 6.../ 7.../ 8.../

9...L-E have been designed for the
combustion of light fuel oil EL.
The burners should be installed and
taken into opera tion by qualifi ed pers on­nel only who will be responsible for the
proper performance of this work in
accordance with the applicable regulati­ons and guidelines.

Any repair work on monitors, limiters
and automatic furnace controllers and
on the other sa fety f aci lities are allowed
to be done only by the manufacturers
themselves or specialists authorized by
them. Original parts should only be
exchanged by a duly qualified specia­list.

Standards and regula tion s

The following standard s sho ul d be
observed in the interest of a safe, easy­on-the-environment and energy-saving
operation of the burner:

According to DIN 4755, the user must
be instructed in the ope rati on o f the bur­ner.

For the installation of an oil furnace
system, care should be taken to
observe DIN 4755, TRbF (Technical
Regulation on Combustib le Liquids) and
the local furnace construction regulati­ons applicable in the country.

Place of installation

The burner must not be operated in
rooms containing aggressive vapours
(e.g. spray, perchloroethylene, hydro­carbon tetrachloride, solvent, etc.) or
tending to heavy dust formation or high
air humidity.
Adequate ventilation must be prov id ed
at the place of installation of the furnace
system to ensure a reliable supply with
combustion air.

Maintenance

The furnace system should be serviced
at least once a year by an authorized
specialist. It is recommended to con­clude a maintenance agreement to this
effect.

Warranty

Manufacturer will not accept any war­ranty if the operating instructions have
not been duly observed in the start-up
and maintenance of the burner and
damages have been caused by impro­per installation, incorrect adjustment,
unauthorized interference or operating
errors.

Product description

The burners of type EK 6.../EK 7.../EK

8.../EK9...L-E can be used for the com­bustion of light fuel oil EL according DIN
51603-1.
The burners are equipped with combu­stion air fan and air pr essure swit ch with
test key, windbox with actuator for the
air control dampers, oil pressure atomi­zer with oil high-pressure pump, nozzle
rod, return nozzle and oil hydraulics
block (with pressure sw it ches, valves
and control shaft), pressure hoses and
electric ignition system.
The burners are designed to operate
with an electronic compound control
system.

EN267/
DIN4787

Oil atomizer burners

VDE 0116 Electrical Equipment

of furnace

4

Technical Data Sheet
Monoblock Oil Burner

EK 6.170 / 200 L-E

Technical Data

Burner output
Fuel flow rate
Operating mode
Type of fuel
Burner control box
Flame sensor
Fan motor

Pump unit

Gear output
Pressure
Nozzle rod
Nozzle
Oil hoses / External connection
Actuator
Ignition transformer
Weight

Operating range EK 6.170 / 200 L-E

0

2

4

6

8

10

12

14

16

18

20

0 500 1000 1500 2000 2500

6.170 L 6.200 L

Q Burner output [kW]

F

Air temperature 20°C, test values according to EN 267 (DIN 4787) at 171 m
above sea level

Pressure in

c

ombus

t

ion

c

hamb er [mb ar]

6.170 L-E

501 - 1800 kW
42 - 152 kg/h
fully modulating
Light oil EL
BCS / LAL 2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50Hz

3,0 kW, 6,4 A, 2800 min-¹

SMG 1945 - 0,75 kW

520 l/h
30 bar
RDN
Thread 7/8"
DN 16 x 1500 / R 1/2"
SAD 15 / STM 40 / MM1004

150 kg

≈

ZA20 140 / ZM20-14

6.200 L-E

640 - 2300 kW
54 - 194 kg/h
fully modulating
Light oil EL
BCS / LAL 2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50Hz

3,0 kW, 6,4 A, 2800 min-¹

SMG 1945 - 0,75 kW

520 l/h
30 bar
RDN
Thread 7/8"
DN 16 x 1500 / R 1/2"
SAD 15 / STM 40 / MM1004

150 kg

≈

ZA20 140 / ZM20-14

No.: 102.880.434203/05

Technical Data

EK 6.170 / 200 L-E

5

Technical Data Sheet
Monoblock Oil Burner

EK 6.240 / 300 L-E

Technical Data

Burner output
Fuel flow rate
Operating mode
Type of fuel
Burner control box
Flame sensor
Fan motor

Pump unit

Gear output
Pressure
Nozzle rod
Nozzle
Oil hoses / External connection
Actuator
Ignition transformer
Weight

Operating range EK 6.240 / 300 L-E

0

5

10

15

20

25

0 500 1000 1500 2000 2500 3000 3500

6.240 L 6.300 L

Q Burner output [kW]

F

Air temperature 20°C, test values according to EN 267 (DIN 4787) at 171 m
above sea level

Pressure in

c

ombus

t

ion

c

hamb er [mb ar]

6.240 L-E

681 - 2500 kW
57 - 210 kg/h
fully modulating
Light oil EL
BCS / LAL 2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50Hz

4,0 kW, 8,5 A, 2800 min-¹

SMG 16026 - 1,1 kW

735 l/h
30 bar
RDN
Thread 7/8"
DN 20 x 1500 / R 1/2"
SAD 15 / STM 40 / MM1004

160 kg

≈

ZA20 140 / ZM20-14

6.300 L-E

940 - 3250 kW
79 - 280 kg/h
fully modulating
Light oil EL
BCS / LAL 2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50Hz

4,0 kW, 8,5 A, 2800 min-¹

SMG 16026 - 1,1 kW

735 l/h
30 bar
RDN
Thread 7/8"
DN 20 x 1500 / R 1/2"
SAD 15 / STM 40 / MM1004

160 kg

≈

ZA20 140 / ZM20-14

No.: 102.880.435303/05

Technical Data

EK 6.240 / 300 L-E

6

Technical Data Sheet
Monoblock Oil Burner

EK 7... L-E

Technical Data

Burner output
Fuel flow rate
Operating mode
Type of fuel
Burner control box
Flame sensor
Fan motor

Pump unit

Gear output
Pressure
Nozzle rod
Nozzle
Oil hoses / External connection
Actuator
Ignition transformer
Weight

Operating range EK 7... L-E

0

5

10

15

20

25

30

0 1000 2000 3000 4000 5000 6000

7.350 L 7.450 L

Q Burner output [kW]

F

Air temperature 20°C, test values according to EN 267 (DIN 4787) at 171 m
above sea level

Pressure in

c

ombus

t

ion

c

hamb er [mb ar]

7.350 L-E

1115 - 4500 kW
94 - 380 kg/h
fully modulating
Light oil EL
BCS / LAL 2.2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50 Hz

5,5 kW, 11,7 A, 2800 min-¹

KL-TA 4C - 2,2 kW
SMG 19065 - 1,5 kW

800 l/h / 900 l/h
30 bar
RDG 1250
Thread M14
DN 20 x 1500 / R 3/4"
SAD 15 / STM 40 / MM1004 / EA2

250 kg

≈

ZA20 140 / ZM20-14

7.450 L-E

1300 - 5300 kW
110 - 447 kg/h
fully modulating
Light oil EL
BCS / LAL 2.2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50 Hz

7,5 kW, 15,5 A, 2800 min-¹

KL-TA 5C - 2,2 kW
SMG 1629 - 2,2 kW

1200 l/h
30 bar
RDG 1250
Thread M14
DN 20 x 1500 / R 3/4"
SAD 15 / STM 40 / MM1004 / EA2

250 kg

≈

ZA20 140 / ZM20-14

No.: 102.880.436403/05

Technical Data

EK 7... L-E

7

Technical Data Sheet
Monoblock Oil Burner

EK 8... L-E

Technical Data

Burner output
Fuel flow rate
Operating mode
Type of fuel
Burner control box
Flame sensor
Fan motor

Pump unit

Gear output
Pressure
Nozzle rod
Nozzle
Oil hoses / External connection
Actuator
Ignition transformer
Weight

Operating range EK 8... L-E

0

5

10

15

20

25

30

0 1000 2000 3000 4000 5000 6000 7000 8000 9000

8.550 L 8.700 L

Q Burner output [kW]

F

Air temperature 20°C, test values according to EN 267 (DIN 4787) at 171 m
above sea level

Pressure in

c

ombus

t

ion

c

hamb er [mb ar]

8.550 L-E

2000 - 6049 kW
168 - 510 kg/h
fully modulating
Light oil EL
BCS / LAL 2.2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50 Hz

11 kW, 22,5 A, 2800 min-¹

KL-TA 5C - 2,2 kW
SMG 1629 - 2,2 kW

1200 l/h
30 bar
RDG 1250
Thread M14
DN 20 x 1500 / R 3/4"
SAD 15 / STM 40 / MM1004 / EA2

320 kg

≈

ZA20 140 / ZM20-14

8.700 L-E

2000 - 7672 kW
168 - 647 kg/h
fully modulating
Light oil EL
BCS / LAL 2.2 / LOK 16
QRB 3 / RAR 7
400 / 690 V, 50 Hz

15 kW, 30 A, 2800 min-¹

KL-TA 3C - 3,0 kW
SMG 1630 - 3,0 kW

1700 l/h
30 bar
RDG 1250
Thread M14
DN 25 x 1500 / R 1"
SAD 15 / STM 40 / MM1004 / EA2

350 kg

≈

ZA20 140 / ZM20-14

No.: 102.880.437503/05

Technical Data

EK 8... L-E

8

Technical Data Sheet
Monoblock Oil Burner

EK 9... L-E

Technical Data

Burner output
Fuel flow rate
Operating mode
Type of fuel
Burner control box
Flame sensor
Fan motor

Pump unit

Gear output
Pressure
Nozzle rod
Nozzle
Oil hoses / External connection
Actuator
Ignition transformer
Weight

Operating range EK 9... L-E

0

5

10

15

20

25

30

0 2000 4000 6000 8000 10000 12000

9.850 L 9.1000 L

Q Burner output [kW]

F

Air temperature 20°C, test values according to EN 267 (DIN 4787) at 171 m
above sea level

Pr

essure in c

ombustio

n cha

m

b

e

r [m

b

ar]

9. 850 L-E

2574 - 9596 kW

217 - 809 kg/h

fully modulating

Light oil EL

BCS / LAL 2.2 / LOK 16

QRB 3 / RAR 7

400 / 690 V, 50 Hz
18,5 kW, 35 A, 2800 min-¹

KL-T 4C
SMG 1631 - 4,0 kW

2250 l/h / 2200 l/h

30 bar

RDG 1250

Thread M14

DN 25 x 1500 / R 1"

SAD 15 / STM 40 / MM1004 / EA2

450 kg

≈

ZA20 140 / ZM20-14

9.1000 L-E

2490 - 11409 kW

210 - 962 kg/h

fully modulating

Light oil EL

BCS / LAL 2.2 / LOK 16

QRB 3 / RAR 7

400 / 690 V, 50 Hz
22 kW, 42,5 A, 2800 min-¹

KL-T 4C
SMG 1631- 4,0 kW

2250 l/h / 2200 l/h

30 bar

RDG 1250

Thread M14

DN 25 x 1500 / R 1"

SAD 15 / STM 40 / MM1004 / EA2

490 kg

≈

ZA20 140 / ZM20-14

No.: 102.880.438603/05

Technical Data

EK 9... L-E

9

Overview

Dimensioned Drawings
EK 6... L-E

EK 6.170/200 L-E

Dimensions in boiler connection plate

EK 6.240/300 L-E

Dimensions in boiler connection plate

10

Overview

Dimensioned Drawings
EK 7... / 8... L-E

EK 7.350/450 L-E

Dimensions in boiler connection plate

Type

EK 8.550/700 L-E

Dimensions in boiler connecti on plate

Type

11

Overview

Dimensioned Drawings
EK 9... L-E

EK 9.850/1000 L-E

Dimensions in boiler connection plate

Type

12

Operation
Start-up Mode

Oil Operating Mode
General Safety Functions

Start-up mode

As soon as the furnace system is requi­red to supply heat the bur ner c ont rol c ir­cuit will clo se and the program be
started. After the prog ram has ru n down
the burner will start.

The air damper is closed when the

burner is out of operation.

The automatic furnace controller con­trols and monitors the starting function.
The electric actuator opens the closed
air damper to its full-load position so
that the burner will sweep the furnace
compartment and exhaust ports at t he
required air flow rates. Shortly after the
pre-ventilation pro cess has been star ted
the lack-of-air cut-out must change ov er
to operating position within a certain
time, i.e. the minimum air pressure set­ting must be reached and maintained
until the burner is turned off. At the end
of the specified pre-ventilation time the
air damper will be moved into its par tial­load position. This operation will be fol­lowed by the pre- igniti on proc edure and
the oil feed start.

The solenoid valves will open and thus
allow the pressurized oil to flow to the
nozzle and to t he return line. The oil will
be atomized, mixe d with the combus tion
air and ignited.
A safety period is provided to allow the
flame to develop a proper and steady
pattern. On the terminati on of the safety
period, a flame signal must have been
received by the automatic furnace con­troller via the flame monitor and remain
on until the regular shut-of f. The start-up
program of the burner has now been
completed.

Oil operating mode

After the flame has developed the load
regulator will be enabled which brings
the burner into its operating position.
The load regulator will now control the
burner automatically between its partial­load and full-load stages.

Depending on the heat rate required the
servomotor will via the controller be
given an "open" or "close" signal and
thus increase or decre ase the oil and air
flow rates.
This compound c ontrol conc ept will v ary
the position of the oil control valve and

air damper and thus adjust the oil flow
rate in relation to the air flow rate.
The stepless control will allow the bur­ner to be operated at any desired stage
between its partial-load and full-load
positions. The burner will be turned off
from its partial-load position. The air
damper will be closed when the burner
is out of operation and will thus prevent
cold air flowing through the burner
chamber, heat exchanger and chimney.
The interior cooling losses will be grea­tly minimized.

General safety functions

In case a flame does not develop when
starting the burner (fuel release) the
burner will shut off at the end of the
safety period (shut-off on trouble). A
shut-off on trouble will also occur in the
case of flame f ailure during oper ation,
air flow failure during the pre - ven til ati on
phase and pressure failure during the
whole period of burner operation. Any
failure of the flame signal at the end of
the safety period and a flame signal
during the pre-ventilation phase (exter­nal light control) will result in a shut-off

on trouble with the automatic furnace
controller being locked. The trouble is
indicated by the trouble signal lamp
lighting up. The automatic furnace con­troller can be unlocked immediately
after a shut-off on trouble by pressing
the unlocking key. The program unit will
return to its starting position and pro­ceed with the restart of the burner.

A voltage failure will result in a regular
shut-off of the burner. Upon voltage
recovery there may be an automatic
restart unless another interlock is provi-

ded, e.g. by the safety system. In any
case of trouble the fu el oil suppl y wi ll be
shut off right away. The program unit
will stop at the same time causing also
the trouble location indicator to stop.
The symbols will indicate the kind of
trouble.
When using the burner control system
type BCS all operational and fault mes­sages may be indicated in plain text on
an optionally available operating and
display module.

Zündung/Ventile
Pumpe

Teillast

EIN

Freigabe

Leistungsregulierung

Betriebsstellung

Vollast

AUS

Oil control

steepless

Full load

Operating position
Load regulator
Release

Partial load

Ignition/valves
Pump

ON OFF

13

Operation

Fuel-air Compound Control
Hydraulic Diagram

Fuel-air compound control

This compound pneumatic control
system with precision-adjustment capa­bility has been designed to allow the
fuel and air flow rates to be steadily
varied in sliding mode for an adjust ment
of the fuel-air ratio over the whole con­trol range.
In the two-stage sliding control concept
the partial-load and full-load positions
are within the control range. Depending
on the heat demand these two load
points will be selected in sliding mode.
A larger fuel feed will not be suddenly
turned on or off. In the stepless control
mode the load will be controlled at any
point within the control rang e dependin g
on the heat demand. The two-stage sli­ding and the stepless control concepts
are different only in the contr ol systems
used with the burners. The same mode
of operation is used for both versions.

Electronic compound control:

The air box includes an actuator for
operating the air dam per . Th e oil co ntrol
valve incorporates an actuator for adju­sting the return oil flow rate and thus th e
output of the burner.
The actuators for the air and fuel flow
control will be operated depending on
output by the electronic compound con­trol which will move them into the pro­grammed positions.

Electronic compound control

Oil feed
Oil return

Air

1a Oil control valve with actuator
1b Air dampers with actuators
2Burner
3Boiler
4 Combustion air fan

14

Operation

Hydraulic Diagram L-E / GL-E
Burner EK 6 - EK 9

120 Air damper
175 Filter
176 Pump
178 Feed solenoid valve
180 Nozzle rod
181 Return solenoid valve
184 Output control valve
187a Pressure re gulating valve

(integrated in pump)
311 Return oil pressure switch
312 Feed oil pressure switch
349 Actuator

In case of TRD 604/72 hr control
items (pos. 311, 312) need to be

tested according to „special construc­tion design“ or must be installed twice.

312

RL

181

175

187 a

VL

176

311

178

178

M M

120

184

349

349

180

181

Hydraulic diagram -DIN / EN

RL

175

187 a

VL

176

311

312

178

178

181

180

181

M

184

120

M

349349

Hydraulic diagram -TRD 604/72 h

15

Operation

Hydraulic Valves and Instruments Group

The hydraulic valves and instruments
group is an integrated concept that
combines several functions of the
hydraulic systems of burners. Its modu­lar construction makes it possible to
meet a wide range of requirements and
conditions of installation. The pump
adapter module (1) allows the hydraulic
valves and instruments group to be
mounted directly to oil burner pumps of
any size. It is fastened to the pump by
means of hollow bolts which are provi-

ded with ¼" screw plugs (4) for venting
the pump when taken into operation.
The basic group module (2) is moun-
ted to the pump adapter with the two
modules being sealed against each
other by O-rings in the supply and
return pipes. Depending on the level of
equipment of the hydraulic system, oil
pressure switches and pr essure gauges
may be installed in the supply and
return pipes of the basic module. The
solenoid valve in the supply pipe is of
servo-assisted type while the return
valve is directly controlled. The soleno­ids of the two valves are electrically
connected i n series which will prevent
one of the valves being opened alon e if
any of the so lenoids is defective. For
the replacement of the solenoid valves
during maintenance work it should be
ensured that the right valve type is
installed in the correct direction of
mounting. For mounting the solenoid
valve in the supply pipe (type 321 H

2520) it must be ensured that the direc­tion of flow shown be a stamped arrow
on the valve flange is the same as the
direction of flow of the oil (from the
pump to the nozzle rod). The solenoid
valve in the return pipe (type 121 G

2520) is marked with a stamped arrow
opposite to the direction of the oil flow
from the nozzle rod back to the pump.

The volume flow control valve installed
in the return pipe consists of a bush
pressed into the hydraulic valves and
instruments group and locked against
torsion and a control shaft. As the con­trol shaft is turned, the contoured confi­guration of the bush and shaft will
change the open cross section for the
oil flowing back and thus vary the oil
return flow rate. Control shafts with dif­ferent control contour parameters are
available for adjustment to various oil
nozzle sizes. This c onc ept ensures that
an excellent control characteristic and a
wide control range can be c overe d for a
great variety of applicatio ns. The co ntrol
contour parameter is affixed to the con­trol shaft by means of an electric mar­ker. The current position of the control
shaft is indicated by the position display.
From the "min." mark (low load of bur­ner) the control shaft will turn clockwise
to the "max." mark (full load of burner).
If the control shaft has been removed
during maint enance work care shou ld
be taken when reinstalling it to ensure
the right mounting position o f the co ntrol
contour by observing the centre punch
mark on the shaft end face. In the low
load position (min.) the centre punch
mark will in any case point up (12
o'clock position - see figure).
If the hydraulic valves and instr uments
group is used in conju nctio n with nozzle
rods not approved as safety shut-off
valve according to EN 264, an exten-
sion module (3) is available which
incorporates an additional solenoid
valve each in the supply and return
pipes. The ex tension module is atta­ched directly to the basic module. The
modules are sealed against each other
by O-rings.
Metal hoses are used for connection
between the hydraulic valves and
instruments group and the nozzle rod.
The hose lines must be protected
against exterior mechanical damage.
The hoses must be positioned and
mounted in accordance with the appli­cable technical standards. For the
installation care must be taken not to
introduce torsional or buckling stresses
neither by the mounting procedure nor
by movements at a later stage. Speci­fied bending radii of the h ose s m us t not
be changed.

Pumpadapter

4

Basic module

Extension module

Control shaft installation

Complete hydraulic valves and

1

2

3

instruments group

16

Start-up

Burner Head Settings
EK 6... L-R/E

EK 6.170 L-R/E EK 6.200 L-R/E

EK 6.240 L-R/E EK 6.300 L-R/E

17

Start-up

Burner Head Settings
EK 7... / 8... L-R/E

EK 7.350 L-R/E EK 7.450 L-R/E

EK 8.550 L-R/EEK 8.550 L-R/E EK 8.700 L-R/E

18

Start-up

Burner Head Settings
EK 9... L-R/E

EK 9.850 L-R/E EK 9.1000 L-R/E

19

Installation
Mounting to Boiler

Electrical Connection
Presetting

Burner mounting

For mounting the burner to the boiler
make sure the connection plate has
been prepared according to the dimen­sions given in the technical datas heets.

• Install the stud bol ts in the connection
plate.

• Put the insulating backing and burner
in place and fasten by bolts.

Check before burner installation

1. Select the nozzle according to

boiler output and combustion
chamber geometry.

2. Set the mixing and ignition unit

according to the boiler output.
For the standard factory setting
refer to the burner head settings.

3. Set the ignition electrodes on the

nozzle.

4. Check the burner tub e ins t a lla tion

depth according to the data speci­fied by the burner and boiler
manufacturers.

Electrical connection

The electrical connection work compri­sing all the installation materials, termi­nals and eart h connections must be
carried out in accordance with the appli­cable regulations. For the electrical
installation of the burner care must be
taken to observe the circuit diagram
made out for the furnace system.
The electrical connection of the burner
and gas valves a nd instrume nts shal l be
entrusted to authorized specialists only.

NOTE: For the installation of the con­nection cables care must be taken to
provide cable loops of sufficient length
to allow for the swing-out of the boiler
door and burner .
Make sure after the completion of the
electrical connection work to check the
wiring of the electrical system of the
burner. This should include a check of
the direction of rotation of the burner
motor (fan).

Boiler inspection glass cooling

For cooling and cleaning the boiler
inspection glass a cooling line (e.g.
hose) may be installed from the burner
to the inspection glass. The burner is
provided with a connection socket for
this purpose.

approx. 6 mm

approx. 15 mm

approx. 10 mm

20

Installation

Boiler lining for Burner L-R/E

Boiler lining

Example of boiler lining for three-pass
boilers:

The space between the flame tube of
the burner φD and the boiler lining φ D1
must be packed wi th heat-resistant
material, e.g. Cerafelt.

This space is not allowed to be lined
with brickwork.

Boiler lining

Example of boiler lining for reve rse-flo w
boilers:

T1 according to the boiler or burner
manufacturer’s instructions.

The space between the flame tube of
the burner φD and the boiler lining φ D1
must be packed wi th heat-resistant
material, e.g. Cerafelt.

This space is not allowed to be lined
with brickwork.

Burner type Dimension A Dimension T φD φD1

Standard 100 ext. 200 ext. (Standard)

EK 6.170 230 330 430 230 227 290
EK 6.200 230 330 430 230 227 290
EK 6.240 250 350 450 250 263 290
EK 6.300 250 350 450 250 263 290
EK 7.350 282 382 482 282 306 360
EK 7.450 282 382 482 282 325 360
EK 8.550 362 462 562 362 346 400
EK 8.700 362 462 562 362 369 400
EK 9.850 395 495 595 395 431 475
EK 9.1000 395 495 595 395 431 475

Boiler lining

21

Installation

Oil Connection
Oil Pressure Control (Feed)

Oil connection

Hoses are used for connection to the oil
lines and stop valves. The hoses must
be installed according to the applicable
standards (relieved of tensile load, free
of distortion) to avoid kinking and
exclude the danger of breakage. Take
care when mounting the oil lines to
bring their ends as close to the burners
as possible and to arrange them in a
way that the boiler door and the burner
can be swung out without any obstruc-

tion.
Refer to the techni cal docum entation f or
the line dimensions for the feed and
return lines from the stop valves to the
tank.

Oil filter

A filter must be inst alled upstream of the
pump to protect the oil pressure pump
and the hydraulic system.

Installation options

• Two-line installation
(separate feed and retu rn lines withou t
delivery pump)

• Ring line system
(with delivery pump and gas-air sepa­rator)

Instrument mounting

Prior to adjusting the burner make sure
to mount the test pressure gauges for
measuring the feed pressure ( Item 2)
and return pressure (Item 1).

A vacuum gauge and pressure gauge
are mounted to the oil pump for measu­ring the oil pressure.

NOTE: After the burner has been tak en
into operation the gauges must be
removed again and the connections
sealed with suitable means. If the gau­ges are mounted to remain on the bur­ner they should be fitted with stop
valves.

Oil pressure control (feed)

The feed pressure is controlled by
means of the pressure regulator instal­led in the pump and should be set at
approx. 25 to 30 bar depending on bur­ner output and nozzle make. The pres­sure regulator is operated by turning its
screw. Make sure to fill the pump with
oil prior to taking into operation.

Pump bleeding

Open the feed and return stop valves
and ensure the ring line (if any) is in
operation. Reduce the oil pressure at
the pressure regulating valve. Turn on
the pump by pressing the contactor.
Check the pump for proper direction of
rotation. Check for proper oil delivery
and absence of leaks in the hy draulic oil
system. For bleeding the pump open
the pressure gauge connection, for
example. When taking the burner into
operation proceed by gradually increa­sing the pressure to operating level (25­30 bar).

Checking the pressure (oil suction
pressure)

The maximum permissible vac uu m is

0.2 bar . At higher vac uum levels t he fuel

oil will tend to gas evolution which may
lead to operating tro uble. In the ring line
mode of operation the pump oil pres­sure is not allowed to exceed 5 bar.

Range of application of oil hoses

Burner type DN Lenght

[mm]

Connection

on both ends

Minimum bending

radius [mm]
EK 6.170/200 16 1500 R 1/2" 230
EK 6.240 20 1500 R 1/2" 230
EK 6.300 20 1500 R 1/2" 240
EK 7 20 1500 R 3/4" 240
EK 8.550 20 1500 R 3/4" 240
EK 8.700 25 1500 R 1" 250
EK 9 25 1500 R 1" 250

1

2

22

Start-up

Return Nozzle Rod Type RDN
Burner Type EK 6

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23

Start-up

Nozzle Selection, Type W2-50°

Return nozzle

The nozzle type Fluidics W is a return
nozzle with i ntegrated spring-loaded
cut-off needle. The throughput rate is
controlled by varying the return pres­sure while keeping the supply pressure
at a constant level.
Prior to burner start, check the nozzle
size against the required out put. It might
be necessary to replace the nozzle (see
nozzle selection diagram).

Nozzle selection diagram

The diagram shows the maximum
throughput rates of th e return no zzles in
dependence of the supply oil pressure.

Supply oil pressure: min. 20 bar

max. 30 bar
Nominal supply oil
pressure: 28 bar
Return oil p ressure: min. 8 bar

Example

Required oil throughput
rate 238 kg/h
Nozzle size accord ing
to diagram W2-225
Supply pressure according
to diagram 28 bar

W 100

W 115

W 130

W 145

W 160

W 180

W 200

W 225

W 250

W 275

W 300

0

50

100

150

200

250

300

350

20 21 2 2 23 24 25 26 27 28 29 30

Vorlauf Öldruck [bar]

Öldurchsatz [kg/h]

Throughput rates shall apply to closed return
Density: 840 kg/m

3

Viscosity: 5 mm2/s
Nozzle type: W2-50°

Oil throughput rate [kg/h]

Supply oil pressure [bar]

24

Start-up

Return Nozzle Rod RDG 1250

Function description

The return nozzle rod RDG 1250 is for
return nozzle without integrated needle
valve and comes with M14 screw con­nection (for example Sonic DZ 100 0,
CBM M14).The locking mechanism
consisted of a slider with se al ring (Pos.
2 and 6) in the forward flow section and
a needle valve (Pos. 5) in the return
flow section, using the sliding rod con­trol by a hydraulic con trol- piston syst em
located at the back of the nozzle rod.
The opening pressure of RDG 1250 is
about 3 bar in forward flow section or 13
to 20 bar in return flow section. When
the solenoid valves are open, the pres­sure from the oil would retract the con­trol-piston via the pressure channel
(Pos. 7) and then push open the slider .

Both the control-piston and sliding rod
with needle valve wou ld remain open as
long as there is an exi sting oil pres sure.
The same oil pressure would keep the
slider open. Under normal circum­stances, both lock in g mec han isms
would open at the same time. The oil in
the forward flow section would exit
through the nozzle head to be mixed
with the air for combustion. The remai­ning oil would be red ire cte d t hrou gh th e
return holes of the nozzle back into the
return flow section of the nozzle rod
assembly. When it is not in operation,
the swirl plate in the nozzle head blocks
the return flow.The return oil flow rate
can be adjusted accordingly using a
pressure control valve If the pump pres­sure is too low (<20 bar), thereby pre­venting the control needle from opening
all the way, variations in throughput are
to be expected as the needle position
will affect the return oil fl ow.

Control-piston openi ng distanc e H is set
in the factory at 9mm. Any adjustment
at installation site is not necessary.

1

5

3

6

4

7

2

+

The Control piston
opens at ca. 13 bar;
Fully open at 20 bar.
Close at 10 bar.

1 Return Nozzle
2 Slider
3 Spring (Forward)
4 Sliding rod
5 Needle valve
6 Seal ring (Forward)
7 Pressure channel
Distance H = 9 mm

Forward

Valve

25

Start up

Nozzle selection „Sonic“

160 kg/h

240 kg/h

300 kg/h

350 kg/h

400 kg/h

450 kg/h

500 kg/h

550 kg/h

650 kg/h

700 kg/h

750 kg/h

800 kg/h

850 kg/h

900 kg/h

950 kg/h

1000 kg/h

Diagram - of Sonic-Spray return nozzle DZ 1000-60°
with controlled return
Light fuel Oil
Feed pressure 28bar

Return nozzles of the type Sonic­Spray are availa bl e in different ratin gs
with an angle of spray of 45°, 60° or
80°.

The 45° nozzles are preferably used
for reversed-flow furnaces while the
60° and 80° nozzles are operated in
three-pass boilers and swirl-type
mixing installations, respectively.

Quantity Oil Nozzle [kg/h]

Return Pressure at the Hydraulicblock [bar]

26

Start-up

Checking Procedure

Check the following prior to the
initial operation of the boiler system:

• Take care to observe the operating
instructions supplied by the boiler
manufacturer. The boiler must be
mounted ready for operation.

• Ensure that the heating system is fi lled
with water to capacity.

• Check the complete system for correct
electrical wiring.

• Check the burner motor for correct
direction of rotation.

• Check for the proper setting of the
temperature and pressure controllers,
limiters, safety switches and electrical
limit switches.

• Bleed the fuel-carrying lines (make
sure they are free of air).

• Check tank, lines and oil pump are fil­led with oil and correct oil nozzle is fit­ted.

• Check the oil hydraulic system is free
of leaks.

• Check the exhaust gas ports are ope­ned and adequate fresh air intake is
ensured.

• With burner in starting position check
that air damper is in „CLOSED“ posi­tion.

• Check that automatic furnace control­ler is unlocked and in its original posi­tion.

Prior to the initial oil feed start make
a functional test of the burner
program flow:

Oil system:

• Open all shut-off valves of the oil sup­ply system.

• The oil solenoid valve in the feed line
disconnect on the terminal strip (see
Circuit Diagram).

• Start burner and check program flow
for correct start-up sequence.

1. Fan starts.

2. Pre-ventilating damper.

3. Air pressure check.

4. Partial-load air damper.

5. Ignition.

6. Valves open (disconnec ted valve

remains closed) .

7. Shut-off upon trouble after expiry

of safety period (see automatic
furnace controller).

• Reconnect the valve.

• Unlock the automatic furnace control­ler.

Oil start-up

Open all shut-off valves of oil su pply
system.

• Set fuel selector switch to its „Oil“
position.

• Fill pump with oil.

• Mount pressure gauge in the feed line
and return line.

• Mount the pressure gauge for
checking the pump suction pressure.

Bleeding

Shortly start the burner and check for
proper direction of rota tion. Bleed the oil
line and oil pump.

CAUTION: The hydraulic system has
been filled with test oil by the manufac­turer. This may cause ignition trouble
when initially operating the system. To
protect the pump, the oil pressure con­troller is factory-set at zero pressure.
When starting the burner take care to
increase the oil pressure slowly to the
operating level.

27

Adjusting Instructions

Elektronic Burner Control with
Electronic Compound Controller

BCS

Refer to the documentation supplied
with the electronic compound control
system for the pre-operational work on
the burner, the checking requirements
(e.g. actuators, limit switches, potentio­meters etc.) and the instructions for the
initial operation of the electronic com­pound control system.

Etamatic

28

Adjusting Instructions

Start-up of Burner Control System Type BCS 300
Flame Detecting System Type FLW 05

Description

The electronic burner control system
type BCS 300 is a programmable auto­matic firing controller of modular con­struction with integrated electronic
compound controller. It is designed for
the control and automatic control of oil,
gas and dual-fuel burners of medium to
larger outputs.
The automatic firing controller may be
used for intermittent or continuous
mode of operation and for furnace
systems built according to TRD.
The controller consists of the following
units that communicate via a safety-ori­ented bus system:

- burner controller module type
BCS 300 (attached to burner)

- flame detector module type BCS­FLW 05 (attached to burner)

- fuel and air servomotors

- operating and display unit type
BAM (not required for opera tion of
furnace system)

The system also incorporates a PID
firing rate controller with standard or
servo-control parameterization capabi­lity and a valve leak tester.

Technical data:

Operating voltage: 230 V a.c.
Frequency: 50-60 Hz
Power input:

BCS incl. BAM:<15 VA

FLW 05: <1.5 VA
Back-up fuse: max. 10 AF
Equipment fuse: 6.3 A slow-blow

0.1 A slow-blow

Permissible ambient temperature:

in operation: 0-60 °C

during storage: -20-70 °C

Starting the burner control system
NOTE: The burner control system is

allowed to be started by duly qualified
specialists only. The personnel opera­ting the system should strictly observe
the applicable instructions for start-up.

Before proceeding with the pro­gramming of the system make a check
of its wiring (especially for compliance
with the relevant DIN-VDE standards
and the regulations of the local power
supply company).

The parameterization of the automatic
firing controller programs, the valve leak
test and the firing rate adjustment will
be handled from the operating and dis­play module.

NOTE: For selecting the automatic con­troller programs and adjusti ng the pre­ventilation times care should be taken to
observe the applicable standards.
The fixed safety time settings are not
allowed to be ex ten ded by external s wit­ching operations.

The fuel-air compound curves may be
programmed by means of the operat ing
and control module or a laptop compu­ter.
If the compound controller is adjusted
by means of the operating and display
module it will only be possible to correct
the curve point settings.
A completely new curve and the defini­tion of new curve points can be achie­ved with the aid of a laptop computer
only.

After the automatic controller programs
have been set it will be possible to
check the inputs and outputs of the bur­ner control system for proper
functioning via the operating and dis­play module.

NOTE: For the tests, all manual fuel
shut-off valves must be kept in closed
position in any case.

The compound modules are provided
with a basic curve when delivered ex
works. This may be changed by means
of the operating and control module to
adjust it to the local conditions. For this
purpose, it is possible to correct the
damper positions for the 10 index points
in the range from 10, 20, 30, etc . to 100.

Flame detecting system

The flame detector m odule type FL W 05
is used in conjunction with the burner
control system.
The following flame sensors may be
connected to the flame detector
module:

-QRA 2

- QRA 53/55

- RAR 7/8

- ionization electrode

- any flame detector with contact
output

The sensor to be used will be selected
by appropriate programming i n the bur­ner control system. The type of sensor
used will depend on the burner opera­ting mode (continuous or intermittent).
The flame boosters integrated in the
flame detector will be checked for pro­per operation at an interval of 90
seconds in continuous mode.
Flame detectors with conta c t output
must if run in c onti nu ous m od e b e intrin­sically safe because only the parts of
the BCS flame detect or a r e ch ec ked fo r
safe operation.

The intensity of the flame signals (UV
sensor, light sensor, ionization elec­trode) is evaluated in the burner control
system and indicated on the operating
and display module.
This allows an exact orientation of the
flame sensors.
It is not possible to measure the flame
intensity by means of instruments.

The flame sensors must be ch ecked for
accumulation of dirt at re gul ar intervals.
Take care that the sensor window is
kept free of dust all the time.
The flame intensity display may be used
as an indicator for the dirt ac cu mul ati on
load.
If the situation cannot be remedied by
cleaning it will be necessary to replace
the flame sensor.

29

Adjusting Instructions
Start-up of Burner Control System Type

BCS 300
Servomotor Type SAD 15.0

The electronic compound control
system type BCS makes use of digitally
activated servomotors type SAD 15.0.
These consist of a stepping motor with
electronic trigger and power pack.
A driver with digital feedback via enco­der disk is provided for monitoring the
function and direction of rotation.
Take care to observe the instruction for
operation for the burner control system
type BCS 300.

Dimensions:

Connection:

P1 : N, L, PE
P2, P3: 1 - EA SA

2 - EB SB
3 - OK WD
4 - GND
5 - AA MA
6 - AB MB

NOTE: Check the zero position of the
servomotors prior to start-up.

Technical documentation:

BCS 300, Dungs

Technical data:

Maximum torque 15 Nm
Gear reduction 745:1
Positioning times (at 200 Hz) 22.3s/90°

Positioning accuracy <±0.3°
Direction of rotation from zero mark to 90°counterclockwise (looking on drive

shaft)

Angular re solution stepping mo tor 0.02°

rotation monitoring 1°

Unidirectional positioning by external load

initial stress at 0.6 Nm
Supply voltage 230 V a.c. +10/-15%, 50 Hz
Current decrease 20 ms ±30% (after last step)
Protection classification IP 54
Shaft, flanged with cylindrical pin 12 dia.

h8

Ambient temperature in operation -20 to +60 °C

Cable gland with PG 11
conduit thread

and earthing

Through hole for M6 thread

P1

N L PE

P3 P2 zu

30

Adjusting Instructions

Electrical Actuator STM 40

The actuator STM 40 is us ed i n co nne c­tion with the electronic burner control

systems of the firm „Lamtec“.

Technical data:

Voltage: 230V AC
Frequency: 50 Hz
Angle of rotation: 90°
Running time: 40 sec. for 90°
Torque: 15 Nm
Static holding
moment: 8 Nm
Dimensiones
(B x H x T): (93 mm x 144 mm x 149 mm)
Potentiometer
(integrated): 5 kΩ

5 k

Ω

31

Start-up

Starting the BCS, Etamatic, VMS/FMS Electronic
Compound Controller

Starting the electronic compound
controller

For starting the electronic ratio control­ler make sure to proceed as described
in the operating instructions.

NOTE:

Only duly qualified personnel must be
employed for starting the controller.
For the initial operation make a check
that the controller settings are in line
with the furnace system requirements.
The configuration of the compound con­troller is shown on the sticker attached
to the housing side wall.

Functional test without burner start

After the electronic compound co ntroller
has been connected electrically pro­ceed with adjusting the potentiometers
of the actuators. Start the fan for
checking the feedback of the fan speed
(press the fan contactor).
As soon as the potentiometer feedback
data have been properly set proceed
with programming the compound con­troller. An exact description of the pro­gramming procedure can be found in
the operation manual supplied with the
compound controller.

NOTE:

The start-up manual of the compound
controller contains information on
trouble signals, detailed instructions for
start-up and for programming the con­troller.

32

Adjusting Instructions

Oil Pressure Switch
Air Pressure Switch

Oil pressure switch

Oil pressure switches are provided to
burners for monitoring the oil pressure.
Depending on the b urner design, the oil
pressure switches can be installed eit­her in the return line only or in both the
return line and feed line. The cut-out
pressure will be selected depending on
the burner system data (ring line pres­sure, oil nozz le, etc.).

Oil pressure damper

An oil pressure damper or a capillary
pipe may be installed in the connection
fitting (2) to make up for oil pressure
variations.

Operating pressure adjustment

For adjusting the operating pressure,
remove the setting know (1) b y pul ling i t
upward and reinstall it again the other
way round. After the adjustment has
been completed mak e sure to instal l the
setting know in its original position
again.

Switching difference

The switching difference may be selec­ted on the pressure switches within the
limits shown in the table. For the adjust­ment, turn the threaded pin in the set
screw (3) for the switching point. One
turn will change the switching difference
by approx. 20 % of the total ra nge of the
switching difference. The oil pressure
switch has a facility for attaching a seal.

1

2

3

Type

Setting

range

Switching
difference

Location

DSB 143 F... 0 - 6 bar 0,3 - 1,6 bar Return line acc. to DIN / EN

DSB(F) 170 F... 15 - 40 bar 1,2 - 4,5 bar Feed line acc. to DIN/EN in pumps

without quick-action stop valve

DSF 146 F... 0 - 10 bar 0,5 - 2,5 bar Return line acc. to TRD 604/ 72h

DSB 158 F... 3 - 25 bar 1,0 - 4,3 bar Feed line acc. to TRD 604/ 72h

Air pressure switch

The air pressure switch is provided for
monitoring the pressure of the combu­stion air fan.
The pressure switch DL 50A has been
designed for switchi ng on, of f or ov er an
electric circuit in the case of changes of
the actual pressure levels from the set­point setting. The pressure switch DL
50A can be used as overpressure,
vacuum or differential press ure mo nit or
for air and non-aggressive gases but
not for gases according to DVGW
Worksheet G 260/l.

Determining the differential pre­flushing pressure and adjusting the
differential pressure switch

• Burner in the pre-aeration phase.

• Measure pressure on test
connection (2).

• Measure vacuum on test
connection (3).

• Add the measured pressures.

• Set the scale to 90% of the calculated
value.

Certification

The pressure switch has been tested in
accordance with DIN 3398 Part 2 and is
registered by CE/DIN-DVGW. It has
been registered in other important gas
consumption countries.

Switch function test

Test buttons are provided to check the
switch functions for proper operation
(with safety cut-out and interlock). The
burner is normally run in partial-load
condition when testing the safety
functions. On pressing button (4) the
vacuum will be removed which causes
the different ial pressure to drop below
the required level. If it is necessary to
test the pressure switc h functio ns under
full-load condition s this may be done by
pressing button (1).

33

Operation

Automatic Furnace Controller LAL... / LOK...
Regulator KS 92

The automatic furnace controlle rs LAL...
and LOK... are designed to control and
monitor burners of stepless or modula­ting mode of operation. For a detailed
functional description of the automatic
furnace controllers with technical data
and design information see the enclos­ure hereto and further descriptive mate­rial.

Technical documents

LAL 2.25
LOK 16 L & G 7785 June 1996

Funktional diagram LAL ... / LOK ...

A = Start command
A-B = Flame formation interval
B = Burner operating position

has been reac hed

B-C = Burner operation (heat

generation)
C-D = Regular shut-off
t1 Pre-flushing time
t2 Safety period
t3 Short pre-ignition time
t4 Option: interval between voltage

on terminal 18 and terminal 19

(valve 1 and 2 will open at the

same time)
t5 Interval between voltage on

terminal 19 and terminal 20

(interval between valve 2 and

controller enable)
t6 After-flushing time
t7 Interval between start command

and voltage on terminal 7
t11 Air damper operating time

(OPEN)
t12 Air damper operating time (MIN)
t13 Permissible after-burning time
t16 Interval to OPEN co mmand fo r air

damper

R Temperature or pressure controller
G Blower motor
Z Ignition transformer
BV Fuel va lve(s)
LR Load controller
LK Air damper
RV Steadily adjustable fuel valve
FS Flame signal

In steplessly variable burners use is
made of the KS 92 industrial controller.
This has specifically been designed for
use with furnace s ystems, preferably for
temperature and pres su re c ontrollers in
conjunction with burners f eaturing
steplessly variable fuel throughput
rates. For adjusting the controller to the
controlled condition, the desired set­point range and the way o f detecting the
actual value, the software configuration
is structured accordingly.

Technical documentation

KS 92 PMA

34

Adjusting Instructions

Flame Monitor
Sensor Current Measurement

Flame monitor with photoresistor

A photoresistor is used as the light-sen­sitive element of the QRB series. The
resistance of this element will decrease
with rising illumination intensity. In the
dark condition the element will develop
a high resist ance, i.e. a re sistanc e in the
M range, whil e under the influence of
light the element will develop a low resi­stance, i.e. in the K range. The after­glow of the f urnace lining will be detec­ted.

Flame monitor with photocell

A selenium cell is used as the light-sen­sitive element of the RAR series. In illu­minated condition this cell will generate
a DC voltage and thus cause a current
to flow to the input of the flame signal
amplifier. Thus, the selenium photocell
sensor is an active sensor. The cell is
insensitive in the infrared r ange so that
light glowing parts of the furnace refrac­tory lining will not be detect ed.

Application

The LAL 2... automatic furnace control­ler with its QRB1/3 flame sensor is
mounted to burners with intermittent
mode of operation which are shut down
within 24 hours.

Application

Burners operated in continuous or inter­mittent mode for pe riods in excess of 24
hours (e.g. boiler sequential control) or
burners operated in steam boilers must
be equipped with the LOK 16... automa­tic furnace controller with its RAR flame
sensor.

Cleaning the sensor

Check the sensor window for possible
accumulation of dirt at regular intervals
and clean if required.
Take care the sensor window is kept
free of dust at any time.
If upon cleaning the sensor does not
properly work it will be required to
replace it by a new one.

Sensor currents

The sensor current is measured to
check the intensity of the lig ht radiation
at the place of installation of the sensor.

Automatic furnace controller

Photoresistor sensor QRB 1/3

QRB 1/3

LAL 2...

Automatic furnace controller

Photocell sensor RAR

LAL 2 / LOK 1 6

Recommended instrument range:
0 - 100 µ A
* See technical data for automatic furnace controller LAL 2 / LOK 16

Automatic controller Minimum

required

Maximum

possible
Monitor with sensor with sensor
* LAL 2.25 (QRB 1/3) 8 µA35 µA
* LAL 2.25 (Q RC 1) 3,9 µA0,8 µA (without flame)
* LOK 16 (RAR...) 6,5 µA25 µA

35

Adjustment

Fan Impeller

The fan impeller can be locked in any
desired position on the motor shaft.
To ensure a high slipping moment take
care that all par t s to be joined are clean
and free of grease.

Removing the fan impeller

NOTE:
Apply a mark on the shaft prior to
removing the fan impeller to ensure
it can be remounted in the same
position.
An axial displacement of the impeller
on the shaft can lead to a reduction
of the fan efficiency with a resultant
lower air flow rate.

For removing the fan impeller unscrew
the bolts (Items 1 a nd 2) and install one
of them in the hole with semi-tapped
thread (Item 3) to act as a forcing
screw. Tighten this bolt to force off of
the bush. Remove the loosened disk
unit by hand w ithout ham mer b lows and
taking care not to damage it.

Mounting the fan impeller

- Clean all bright surfaces and ensure
they are free of grease.

- Mount disk and bush and align the
holes.

- Align the two opposing bolts
(Items 1 and 2) and tighten evenly.

Apply the following tightening
torques:

SM 16, bush no. 1615 hub bores 28
mm: tightening torque 20 Nm.

SM 20, bush no. 2012 hub bores 38 mm
and 42 mm: tightening torque 30 Nm.

SM 25, bush no. 2517 hub bore 42 mm
and 48 mm: tightening torque 50 Nm.

WM 30 bush no. 3030 hub bore48 mm:
tightening torque 90 Nm

fan impeller

suction-funnel

Burner X [mm]

EK 6.170/200 5,5
EK 6.240/300 4
EK 7.350/450 4
EK 8.550 14
EK 8.700 8
EK 9.850/9.1000 15

36

Servicing Instructions

Burner Maintenance

Furnaces should be inspected once
a year. An extract from DIN 4755
reads as follows:

„To ensure a high operational readi­ness, functionality, safety and ec ono­mic efficiency, the user should have
the boiler system inspected by an
authorized person of the manufactu­rer or other specialist once a year.
The whole system must be checked
for proper operation and faults
detected should be rectified without
delay. It is advisable however to
make another inspection of the
system in addition to the one speci­fied herein.“ The inspection should
comprise the following work:

1. Inspect the boiler internals and
insulating packages and replace
by new ones if required. Check
boiler for possible ac cumulation of
dirt.

2. Remove the nozzle, check it and
replace it by new one if required.

3. Clean the ignition electrodes.

4. Check the ignition electrode and
spark functions and readjust if
required.

5. Clean the burn er interior and exte­rior.

6. Clean the fan impeller.

7. Check the fan impeller for possi­ble deformation and cracks.

8. Clean the flame sensor.

9. Clean the filters and screens.

10. Check the electrical connections.

1 1. Check the flame tube and ret arder

disk/swirl element (replace if
required) and check the burner
head setting after such replace­ment

12. Check the control equipment for
proper operation, setting and
safety period.

13. Check the pressure switch for pro­per setting and operation.

14. Check the oil pump by measuring
its pressure and vacuum levels.

15. Check the hydraulic oil system for
absence of leaks.

16. Check the oil hoses for possible
damage and twisting.

17. Clean the air damper and check
for smooth operation.

18. Check the combustion process
and make exhaust gas tests:

• Fuel throughput rate adjustment

• Heating chamber temperature

(intake temperature)

• Exhaust gas temperature

• Pressure in combustion

chamber and exhaust gas pipe

•CO

2

and O2 contents of exhaust

gases

• CO test, soot test

• UV sensor current measurement

19. Enter measured data in test
record.

Removing the mixing unit

For replacing and setting the retarder
and ignition unit it will be necessary to
remove the nozzle rod from the burner
pipe as described below:

• Disconnect the system from it s volt age
source. Set the master switch to
„OFF“.

• Close all shut-off valves upstream of
the burner.

• Remove the housing cover.

• Pull off the ignition cable.

• Remove the flame sensor .

• Loosen the Metal oil hoses on the
hydraulic block connecting to the
RDG 1250. Avoid using exces sive tor­sion on the hydraulic hoses.

• Remove left-hand or right-hand hinge
bolt depending on direction of swivel
(if swivelling unit is provided).

• Loosen locking bolts .

• Swing out burner.

• Demount the nozzle rod.
NOTE: Retarder disk / swirl element
and ignition electrodes are mo unted to
nozzle rod.

Note on re-assembly:

• In the front part of the RDG 1250 is a
forward flow slide that controls oil flow
to the nozzle. To ensure a safe
functioning in this area, no fixtures are
allowed 100mm from th e fro nt e dge of
the nozzle rod assembly. (such as
electrode and baffle holders)

• If you tighten the nut at the hydraulic
hoses, make sure that it is torsi on-free
at the nut. A spanner will have to be
used on the opposite side.
→ Re-assembly must be done in
reverse order.

• After assembly, both function and lea­kage test on the RDG 1250 must be
conducted. Start the burner after all
necessary components were connec­ted and check for leakage. When
flame is establish, stop the bur­ner.Re mov e the burn er cov er an d us e
a torch to check for oil leakage from
the nozzle rod assembly.Leakage
should not be more than a few drops
of oil, as they are from the remaining
oil in the no zzle head.

37

Exhaust Gas Test

Exhaust gas test

T o ensure an economically efficient and trouble-free
operation of the system it will be necessary to
adjust the burner specifically in accordance with the
furnace system. This is achieved by means of a
fuel-combustion air compound control unit which
adjusts the burner to ensure a proper combustion.
Exhaust gas tests are required for this purpose.
The percentage CO

2

and O2 and the exhaust gas

temperature will have to be measured to determine
the efficiency and combustion quality.
Prior to any measurement make sure to check the
boiler and exhaust gas system for absence of
leaks.

Secondary air will falsify the measured results

Check that the exhaust gases have a residual oxy­gen (O

2

) content as low as possible and a carbon

dioxide (CO

2

) content as high as possible.

The carbon monoxide content of the exhaust gases
must be below the currently applicable specificati­ons in all load stages.
In the fuel oil combustion mode the permissible
soot number in the exhaust gas is not allowed to be
exceeded.

Ratio between O2- and CO2- for
light oil EL (CO

2

max =15,40%)

% O

2

% CO2 % O2 % CO2

0,00 15,40 3,00 13,19
0,10 15,33 3,10 13,12
0,20 15,25 3,20 13,04
0,30 15,18 3,30 12,97
0,40 15,11 3,40 12,89
0,50 15,03 3,50 12,82
0,60 14,96 3,60 12,75
0,70 14,88 3,70 12,67
0,80 14,81 3,80 12,60
0,90 14,74 3,90 12,53
1,00 14,66 4,00 12,45
1,10 14,59 4,10 12,38
1,20 14,52 4,20 12,31
1,30 14,44 4,30 12,23
1,40 14,37 4,40 12,16
1,50 14,29 4,50 12,08
1,60 14,22 4,60 12,01
1,70 14,15 4,70 11,94
1,80 14,07 4,80 11,86
1,90 14,00 4,90 11,79
2,00 13,93 5,00 11,72
2,10 13,85 5,10 11,64
2,20 13,78 5,20 11,57
2,30 13,71 5,30 11,49
2,40 13,63 5,40 11,42
2,50 13,56 5,50 11,35
2,60 13,48 5,60 11,27
2,70 13,41 5,70 11,20
2,80 13,34 5,80 11,13
2,90 13,26 5,90 11,05

O221

CO

2max

CO

2gem

–

CO

2max

-----------------------------------------------

× %=

=

O

2

21

CO

2max

CO

2gem

–

CO

2max

-----------------------------------------------

× %=

=

Ratio between O2- and CO2- for
heavy oil (CO

2

max =15,90%)

% O

2

% CO2 % O2 % CO2

0,00 15,90 3,00 13,63
0,10 15,82 3,10 13,55
0,20 15,75 3,20 13,48
0,30 15,67 3,30 13,40
0,40 15,60 3,40 13,33
0,50 15,52 3,50 13,25
0,60 15,45 3,60 13,17
0,70 15,37 3,70 13,10
0,80 15,29 3,80 13,02
0,90 15,22 3,90 12,95
1,00 15,14 4,00 12,87
1,10 15,07 4,10 12,80
1,20 14,99 4,20 12,72
1,30 14,92 4,30 12,64
1,40 14,84 4,40 12,57
1,50 14,76 4,50 12,49
1,60 14,69 4,60 12,42
1,70 14,61 4,70 12,34
1,80 14,54 4,80 12,27
1,90 14,46 4,90 12,19
2,00 14,39 5,00 12,11
2,10 14,31 5,10 12,04
2,20 14,23 5,20 11,96
2,30 14,16 5,30 11,86
2,40 14,08 5,40 11,81
2,50 14,01 5,50 11,74
2,60 13,93 5,60 11,66
2,70 13,86 5,70 11,58
2,80 13,78 5,80 11,51
2,90 13,70 5,90 11,43

O221

2max

CO

2gem

–

CO

2max

---------------------------------------- -

× %=

=

38

Exhaust Gas Test

Trouble Shooting Instructions

Exhaust gas loss

Exhaust gas loss by way of free heat
will occur as a result of th e temperat ure
difference between the fuel-air mixture
entering the furnace chamber and the
gases discharged. Any increase in the
excess of air and the resultant higher
exhaust gas v olume will cause the
exhaust gas loss to rise. The exhaust
gas loss can be calculated as follows:

Example:
Data measured in fuel oil mode:
CO

2

content of exhaust gases 12,8%

Exhaust gas temperature 195°C

Air intake temperature 22°C
The exhaust gas loss can be calcul ated

as follows:

q

A

= exhaust gas loss in %

t

A

= exhaust gas temperature

in °C

t

L

= combustion air temperature

in °C

CO

2

= volumetric content of carbon

dioxide in %

q

A

tAtL–

()

A

1

CO

2

-----------

B

+









⋅

=

Light oilELHeavy oil

S

A

1

= 0,50 0,490

B = 0,007 0,007

In any case of trouble proceed with
checking the basic conditions for a
proper operation of the boiler
system:

1.Is electric power available?

2.Is fuel oil contained in the tank?

3.Are the shut-off valves opened?

4.Are all control and safety inst ruments
such as boiler thermostat, water
supply failure cut-out, limit switches,

etc. properly set?

1. Ignition failure
Cause Remedy

Ignition elec­trode short cir­cuit.

Adjust
electrodes.

Wide ignition
electrode
spacing.

Adjust
electrodes.

Dirty and wet
electrodes.

Clean
electrodes.

Cracked
insulator.

Replace
insulator.

Defective igni­tion transformer.

Replace
transformer.

Defective auto­matic furnace
controller.

Replace
controller.

Burnt ignit ion
cable.

Replace cable;
search for cause
and eliminate.

Pilot burner
failure.

Adjust ignition
gas pressure

Ignition gas
valve does not
open.

Search for
cause and elimi­nate

Defective
solenoid.

Replace

2. Motor running failure
Cause Remedy

Motor protection
relay and fuses.

Check and
replace if
required.

Air pressure
switch not
changed over or
defective.

Check and
replace if
required.

Defective motor. Replace motor.
Defective power

contactor.

Replace
contactor.

Air fan motor
starts but stops
after 20-25 secs.

Check for
solenoid leaks

Air fan motor
starts, but stops
after about 10
secs in pre-ve nti­lating mode.

Air pressure
switch fails to
change over;
replace switch if
defective; clean
switch if dirt has
accumulated;
check electrical
connections.

3. Pump oil delivery failure
Cause Remedy

Shut-off valves
closed.

Open valves.

Filter blocked by
dirt.

Clean filter or

replace cartridge.
Filter leaks. Replace filter
Oil lines leak. Retighten scre-

wed unions; tigh-

ten oil lines.
Suction valve

leaks.

Remove and

clean or replace.
Direction of rota-

tion of pump.

Check irection of

rotation.
Damaged gear-

box.

Replace pump.

Reduced pump
output.

Replace pump.

-Strong mechanical noise.
Pump takes in air Retighten scre-

wed unions.
High vacuum in

oil pipe

Clean filter; fully

open valves.
For heavy oil:

Incorrect oil tem­perature.

Check pre-hea-

ter:

thermostat set-

ting, dirt

39

Trouble Shooting Instructions

8. Cleaning and lubricating
instructions

Depending on the amount of dir t intro­duced by the combustion air it will be
necessary to clean the fan impeller,
ignition electrodes, flame sensors and
air dampers as required.

For burner with mechanical compound
controller:
Lubricate the ball heads of the com­pound controller setting screws with
grease.

The bearing point s of the burner mov ing
parts require no maintenance.
Damages of ball bearings should be
detected and eliminated at an early
stage to avoid greater subsequent
trouble. Listen to the motor bearing
noise to identify possible irregularities.

4. Unsteady atomization
Cause Remedy

Loosened
nozzle.

Tighten nozzle

Hole partly clog­ged.

Remove and
clean or replace.

Worn by long­time use.

Replace by new

one.
Oil flow blokkage
Due to clogged

nozzle.

Remove and

clean.
Nozzle leaking. Replace nozzle.
Shut-off valve in

nozzle rod lea­king.

Replace valve.

5. No respon se to flame by
automatic furnace controller
with flame sensor

Cause Remedy

Dirty flame sen­sor.

Clean flame

sensor.
Burner fails to

start.

Check

connection of

automatic fur-

nace controller.
Trouble lamp

lights; flam e
trouble.

Unlock and

search for cause

Weak flame sen­sor signals.

Check combus-

tion setting.
Burner starts

without flame
formation.
Solenoid valve
fails to open.

Defective coil or

rectifier.

Check connec-

tion.

6. Mixing unit gives poor com­bustion data due to heavy inside
accumulation of oil or coke

Cause Remedy

Incorrect set­tings.

Correct settings.

Incorrect mix­ture ignition unit.

Replace unit.

Nozzle too large
or too small .

Replace nozzle.

Incorrect angle
of spray.

Replace nozzle.

High or low com­bustion air flow
rate.

Readjust burner.

Furnace cham­ber not suf­ficiently
ventilated.

Furnace cham­ber to be ventila­ted through a
non-closed ope­ning with a cross
section of min.
50 % of all chim­ney cross sec­tions of the
furnace system.
Take care to
observe the
application regu­lations.

7. Solenoid valve fails to open

Cause Remedy

Defective coil. Replace coil.
Defective auto-

matic furnace
controller.

Replace auto­matic furnace
controller.

Valve does not
close tightly; dirt
accumulated on
sealing surfaces.

Open valve;
remove foreign
matter; replace
valve if required.

40

Servicing Instructions

Operating Trouble

a - b starting program
b - b’ „idle steps“

contact not actuated)

b(b') - a after-flushing program
The automatic furnace controller may

be unlocked immediately after a shut­off on trouble. After it has been unlok­ked (and after a defect with resultant
operating stop has be en elim inated and
after a voltage f ail ure), the program unit
will in any case return to its starting
position with voltage being only supp­lied to terminals 7, 9, 10 and 11 as pre­set by the control program. It is only at
this stage that the program of the auto­matic furnace controller will restart the
burner.

NOTE:
Do not operate the unlocking unit fo r
more than 20 seconds.

General burner trouble

In the case of a burne r trou ble for which
a cause is not immedi ately obvious, the
program flow should be checked by
reference to the applicable electric cir­cuit diagram and functional description
of the hydraulic system until the source
of trouble can be located.

Electrical burner trouble

Burner trouble situations will be indica­ted by the signal lamp lighting up. The
LAL 1 automatic oil furnace con troller is
provided with a trouble location indica­tor which is very useful in searching for
the cause of the trouble.

Control program in the case of
trouble and trouble signals

For information regarding the LAL 1
automatic oil furnace controller refer to
L and G 7153.

Basically, any trouble w il l c aus e the pro­gram unit and the trouble location indi­cator to stop. The symbol shown above
the reading of the indicator will identify
the type of trouble:

No start, e.g. because the CLOSED
signal from the limit change-over
switch «Z» (or auxiliary switch «M»)
is not available in terminal 8 or a
contact is not closed between termi­nals 4 and 5.

Operating stop because the O PEN
signal from the limit change-over
switch «A» is not available on termi­nal 8. Note that terminals 6, 7 and
15 will remain live un til the trouble is
eliminated.

Shut-off on trouble because of a
fault in the flame monitoring circuit.

Operating stop because the posi­tion signal of the auxiliary switch
«M» for the low-flame po sitio n is n ot
available on terminal 8. Note that
terminals 6, 7 and 15 w ill remain live
until the trouble is eliminated.

1 Shut-off on trouble because a

flame signal is not available on the
expiry of the safety time.

Shut-off on trouble because the
flame signal has faile d during burner
operation.

Shut-off on trouble during or after
the control program flow due to

external light (e.g. by flame not
extinguished, leaking fuel valves or
shut-off valves in the nozzle rod,
fault in flame monitoring circuit, or
similar).

IMPORTANT NOTE: In case of failure
of an automatic furnace controller this
should be replaced by a new one. Do
not attempt any repair work on any parts
of automatic furnace controllers.

Check for proper working order

In case an operating trouble make a
check for proper working conditions.

1. Fuel oil availability.

2. Electric power availability.

3. Proper functional order and set­ting of all control and safety instru­ments such as temperature
controller, safety limiter, water
failure cut-out, electrical limit swit­ches, etc.

41

System Diagram

1 Burner blower
2 Oil filter
3 Stop valve
4 Oil level indicator
5 Suction val ve
6 Tank
7 Leak indicator
8 Quick-acting valve
9 Filling li ne
10 Limit transmitter
1 1 Vent line
12 Pump unit
13 Pressure holding
valvel

Stepless control, with supply pump and ring line system

Stepless control, direct intake

1 Burner blower
2 Oil filter
3Stop valve
4 Oil level indicator
5 Suction valve
6 Tank

7 Leak indicator
8 Quick-acting valve
9 Filling line
10 Limit transmitter
1 1 Vent line

42

43

Customer Service:

ELCO GmbH

D-64546 Mörfelden-Walldorf

ELCO Austria GmbH

A - 2544 Leobersdorf

ELCOTHERM AG

CH - 7324 Vilters

ELCO Rendamax B.V.

NL - 1410 AB Naarden

ELCO Belgium n.v./s.a.

B - 1731 Zellik