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
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