elco RPD 30, RPD 40, RPD 50, RPD 70, RPD 80 Operation Manual

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Page 1

Operation Manual

For the authorized specialist

Dual-fuel Duoblock Burner RPD 30 - 100 GL-R / GS-R

03/2005 102.877.8447

Page 2

Inhalt

General Information .............................................................3

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

Burner Construction ..........................................................10

Mounting the Burner to the Boiler ......................................11

Combustion Air Fan Drive Modes .....................................12

Dimensioned Drawing for RPD Burner 20 - 100 ...............13

Burner scheme Gas train ..................................................15

Hydraulic Scheme .............................................................17

Hydraulic Scheme .............................................................18

Mounting Position Leak Test Ignition Gas Connection

Ignition Burner Type ZT0 ...................................................20

Ignition Gas Solenoid Valve ..............................................24

Oil Connection Fuel Oil Supply .........................................25

Oil Connection ...................................................................26

Medium pressure screw pumps ........................................27

Burner Pump Assembly Electrical Connection ..................29

Return Nozzle Rod DG 75 .................................................30

Return Nozzle Rod MAT ...................................................31

Throughput Rate Charakteristics Light Fuel Oil ................32

Throughput Rate Charakteristics Heavy Fuel Oil ..............40

Dimensions of the Mixing Unit ...........................................49

Draw-out and Swing Mechanism .......................................50

Air Flow Adjustment

Oil Flow and Gas Rate Adjustment ...................................51

Mechanical Compound Controller .....................................52

Pressure Setting ................................................................53

Removal and Replacing the Shaft Seal

of the Return Flow Nozzle Assembly DG 75 .....................54

Oil Pressure Switch Air Pressure Switch ...........................55

Setting Pressure Switches and Control System ................56

Automatic Furnace Controller LFL 1... / LGK 16... ............57

Flame Monitor Sensor Current Measurement ...................58

Actuator Type ARIS, 4, 4a, 5 .............................................59

Solenoid Safety Valves .....................................................60

2/2 Way Valve Type MK 15 ...............................................62

2/2 Way Valve Type MK 20 ...............................................64

Pipe spring - Glycerine - Manometer

Bimetal - Pointer - Temperature controller ........................66

Flushing and Oil Feed Start Thermostat ATH 22 .............67

Gas Connection .................................................................68

Gas Motor Valve VK ..........................................................69

Gas Pressure Regulator ....................................................71

Gas Pressure Regulator ....................................................72

Gas Filter Safety Vent Valve .............................................74

Diagram Pressure Loss .....................................................75

Discharge Speed, Gas Nozzles ........................................76

Preoperational Checks Functional Flow Gas Start-up ......78

Start-up Light Oil ...............................................................79

Start-up Heavy Oil .............................................................80

Viscosity as a Function of Oil Temperature .......................81

Oil Start-up Burner Shutdown

Measures in Case of Trouble ............................... ...... .......82

Exhaust Gas Test ..............................................................83

SO2-content i n Exhaust Gas

from Light Oil and Heavy Oil Combustion .........................84

O2, CO2, Lambda Conversion Table ................................85

O2, CO2, Lambda Conversion Table ................................86

O2, CO2, Lambda Conversion Table ................................87

O2, CO2, Lambda Conversion Table ................................88

Trouble Shooting Instruction s .............. ...... ........................89

Contents

Page 3

General Information

Important information

The burners of type RPD 30...100GL/ GS-E.../R... have been desig ned for the combustion of natural gas or fuel oil. 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.

Only duly authorized specialists should be entrusted with the installation of the gas system.

Any repair work on monitors, limiters and automatic furnace controllers and on the other safety facilities are allow ed 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 tions

The following standards should be observed in the interest of a safe, easyon-the-environment and energy-saving operation of the burner:

According to EN 676 and EN 267, the user must be instruc ted in the operati on of the burner and according to DIN 4755 and DIN 4756, the user must be introducted in to gas firing system.

For the installation of a gas furnace system, care should be taken to observe DIN 4756, TRGI (Technical Regulation on Gas Installations), the Worksheets of DVGW (German Association of the Gas and Water Sector) and the local furnace construction regu lations applicable in the country.

Screwed unions of metal used in gas lines should be fitted with approved sealing elements.

Prior to taking the burner into operation make sure to vent the gas line, but this should in no case be done through the furnace chamber.

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.

Start-up

The furnace system should be started initially by the installer, manufacturer or other specialized personnel. Prior to taking the furnace system into operation, make a test of all automatic control, safety and control facilities for proper functional order and check them for correct setting if of adjustable type. Furthermore, check the control circuits, fans, etc. for proper fuse rating, and whether suitabl e precaution s have bee n taken to prevent accidental contact.

Inspection and Maintenance

The furnace system should be inspected and serviced at least once a y ear by an authorized special ist of the inst al le r to ensure its proper functional order, operational safety and energy-saving operation. Check the system for absence of leaks and functional order. For the combustion anal ysis proceed as described in the section entitled „Exhaust Gas Test“. It is recommende d 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.

Burner installation and accessories

Boiler lining

The boiler lining should be made of heat-resistant materials (temperature resistance >1400°C). T ake care that the burner flame tube is covered by the boiler lining over its full length. The open space between the burner flame tube and the boiler lining should be packed with mineral wool.

Checks prior to burner installation

1 Check the mixing ignition unit

according to the boiler output.

2 Oil nozzles and mixing ignition

unit. 3 Pilot burner setting. 4 See dimensioned drawing for set-

ting dimensions of mixing ignition

unit. 5 Check the air cylinder for proper

function (po ssible damage in

transport). 6 Check the air damper setting

according to flame p attern and fur-

nace chamber geometry.

EN 676/ DIN 4788

Gas burners with bl ower

EN 267/ DIN 4787

Oil atomizer burners

VDE 0116 Electrical Equipment of

furnace

Page 4

Technical Data Sheet Duoblock Dual Fuel Burner

Feld52:

RPD 30 / 40 / 50 GL-R / GS -R

6042

8230

1116 0

954

110 0

1400

2000

4000

6000

8000

10000

12000

RPD 30 RPD 40 RPD 50

Technical Data

Fuel flow rate (light oil) Gas flo w rat e Operating mode Fuel ty p e Automatic burner controller Flame sensor Ignition burner Ignition transformer

Pump output at 35 bar MAT oil control block Oil connection Nozzle rod Nozzle Actuator Gas conn ection

We ight Pre ssure loss i n mixing uni t

Gas contr ol organ

Burner output

Output range

954 - 6042 kW

RPD 30

81 - 513 kg/h

95 - 604 m³/h

fully modulating

Light oil / heavy oil / natura l gas / special fuels

LFL 1., LGK 16 or other approved models

QRA 2, QRA 53 o r other approved models

MAT / Hegwein ZNVL (ZT0)

D-52 L5 KV

Z112 K5

1200 l/h

SRB 19000/30

R 3/4" / 22 mm

MAT / DG 75 MAT - MK 27

WA N 4

R 3"

430 kg

30 mbar or according to diagram

accordi ng to gas pressure

(MAT ignition burner) (Hegwein ignition burne r)

1100 - 8230 kW

RPD 40

98 - 694 kg/h

110 - 823 m³/h

1850 l/h

SRB 19000/40

R 3/4" / 22 mm

MAT / DG 75 MAT - MK 27

WA N 4

R 3"

450 kg

1400 - 11160 kW

RPD 50

118 - 941 kg/h

140 - 1116 m³/h

2400 l/h

SRB 19000/50

R 3/4" / 22 mm

MAT / DG 75 MAT - MK 27

WA N 4

R 5"

600 kg

Technical Data Sheet Duoblock Dual Fuel Burner

RPD 30, 40 & 50 GL-R / GS - R

Page 5

RPD 30, 40 & 50 GL-R / GS - R

Description Dimensions

Operating mode

Fully automatic for ced drau ght dual fuel burner, safety equipment according to EN 267 and EN 676, especially designed for high turn down ratios.

Electric design

Burner pre-wired and ready to connect. All burner components wired to the burner terminal rail. Burner control box supplie d loose for installation in separate contr ol panel. Separate fitted oil pump assembly.

Combustion air

Separate combustion air blower with stable and p ulsation-free characterist ics also on appli ances with a high flue gas resistance. The combustion air volume is divided into a primary and a secon-

dary stream. The flame shape may be adapted by adjustable twist dampers.

Control systems

oil side: adjustable by means of return flow system with compound controller and spill back nozzle. gas side : fuel throughput controlled by compound controller with adjustable cam disc and gas inlet butterfly valve. air side : by means of compound controller with adjustable cam discs for primary air (air dampers) and secondary air (air cylinder).

Monitoring system

Flame monitoring by means of flame sensor and tested burner control box. Combustion air monitoring achieved through differential air pressure switch, resp. speed control switch in cas e of burner with speed control regulation.

Ignition

Direct electric high voltage ignition, 5000 V, by means of an inbuilt ignition burner.

22,5 °

P1 P2

444

RPD 20 - 60

L6 50%

L4 100%

B3 B4 B5W

RPD 70 - 100

Gewinde Länge K

Stift M

Bohrungen Kesselplatte

22,5 °

15°

L5L1

RPDA1B1B2B3B4B5B6B8D1D2D3D4D5D6D7GH1H2H3H4 K L1L4

30 745 78 19 260 375 70 705 416 830 790 385 371 2 90

323,5

17,5 317 620 373 993 650 30 700 124 40 745 78 19 260 375 70 705 416 830 790 423 409 3 40 367 17,5 442 620 373 993 650 30 700 95 50 950 78 19 315 375 70 760 535 1030 990 470 456 380 410 17,5 370 675 475 1150 740 30 770 110

RPD L5 L6 M P1 P2 P3 P4 R T T1 T2 T3 U V W X Y Z LB C FI F2 F3

30 1350 62 12 580 670 320 410 1265 160 192 491 346

22x1,5

3" 248

4x92 5x126

10-----

40 1425 50 12 580 670 320 410 1265 160 192 491 346

22x1,5

3" 248

4x92 5x126

10-----

50 1620 55 12 740 830 416 506 1743 181 250 530 376

22x1,5

5" 319

3x152 5x156

10-----

set screw M length K

Details of boiler front plate

Page 6

Technical Data Sheet Duoblock Dual Fuel Burner

Feld52:

RPD 60 / 70 / 80 GL-R / GS -R

145 11

20470

30350

2232

3590

5500

5000

10000

15000

20000

25000

30000

35000

RPD 60 RPD 70 RPD 80

Technical Data

Fuel flow rate (light oil) Gas flo w rat e Operating mode Fuel ty p e Automatic burner controller Flame sensor Ignition burner Ignition transformer

Pump output at 35 bar MAT oil control block Oil connection Nozzle rod Nozzle Actuator Gas conn ection

We ight Pre ssure loss i n mixing uni t

Gas contr ol organ

Burner output

Output range

2232 - 14511 kW

RPD 60

188 - 1223 kg/h 223 - 1451 m³/h

fully modulating

Light oil / heavy oil / natura l gas / special fuels

LFL 1., LGK 16 or other approved models

QRA 2, QRA 53 o r other approved models

MAT / Hegwein ZNVL (ZT0)

D-52 L5 KV

Z112 K5

3100 l/h

SRB 19000/60

R 3/4" / 22 mm

MAT

MAT - MK 50

WA N 4

R 5"

640 kg

30 mbar or according to diagram

accordi ng to gas pressure

(MAT ignition burner) (Hegwein ignition burne r)

3590 - 20470 kW

RPD 70

303 - 1726 kg/h 359 - 2047 m³/h

4000 l/h SRB 19000/70 R 3/4" / 22 mm

MAT

MAT - MK 50

WA N 4 A

R 5"

900 kg

5500 - 30350 kW

RPD 80

465 - 2559 kg/h 550 - 3035 m³/h

6400 l/h

SRB 19000/80

R 1" / 28 mm

MAT

MAT - MK 50

WA N 4 A

R 8"

1200 kg

Technical Data Sheet Duoblock Dual Fuel Burner

RPD 60, 70 & 80 GL-R / GS - R

Page 7

L6 50%

L4 100%

RPD 20 - 60

P1 P2

B1 444

B3 B4 B5W

15°

Stift M

Gewinde Länge K

Bohrungen Kesselplatte

22,5 °

RPD 70 - 100

RPDA1B1B2B3B4B5B6B8D1D2D3D4D5D6D7 G H1H2H3H4 K L1L4

60 994 78 19 315 375 70 760 622 1080 1040 520 506 420

455,5

18 312 700 497 1197 825 30 735 125

70 1160 78 19 315 375 75 765 731 1240 1200 640 626 520

565,5

18 469 780 580 1360 900 30 740 170

80 1350 75 19 315 375 75 765 860 1450 1400 740 710 597 646 18 600 820 675 1495 1000 30 700 185

RPD L5 L6 M P1 P2 P3 P4 R T T1 T2 T3 U V W X Y Z LB C FI F2 F3

60 1695 62,5 12 750 840 470 560 1760 181 270 555 401

22x1,5

5" 379

4x129 5x160

10 - - - - -

70 1995 85 12 936 1026 600 690 2010 181 365 610 450

28x1,5

5" 410

5x128 7x140

10 - - - - -

80 2285 92 12 1102 1192 700 790 2320 187 310 707 495

28x1,5

8" 489

6x125 9x128

10 - - - - -

RPD 60, 70 & 80 GL-R / GS-R

Description Dimensions

Operating mode

Fully automatic for ced drau ght dual fuel burner, safety equipment according to EN 267 and EN 676, especially designed for high turn down ratios.

Electric design

Combustion air

Separate combustion air blower with stable and p ulsation-free characterist ics also on appli ances with a high flue gas resistance. The combustion air volume

is divided into a primary and a secondary stream. The flame shape may be adapted by adjustable twist dampers.

Control systems

Monitoring system

Ignition

Direct electric high voltage ignition, 5000 V, by means of an inbuilt ignition burner.

set screw M length K

Details of boiler front plate

Page 8

Technical Data Sheet Duoblock Dual Fuel Burner

Feld52:

RPD 90 / 100 GL-R / GS-R

42000

45000

7000 7000

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

RPD 90 RPD 100

Technical Data

Fuel flow rate (light oil) Gas flow rate Operating mode Fuel type Automatic burner cont roller Flame sensor Ignition burner Ignition transformer

Pump output at 35 bar MAT oil control block Oil connection Nozzle rod Nozzle Actuator Gas connection

Weight Pressure loss in mixing unit

Gas control organ

Burner output

Output range

7000 - 42000 kW

RPD 90

590 - 3540 kg/h 700 - 4200 m³/h

fully modulating

Light oil / heavy oil / natural gas / special fuels

LFL 1. , LGK 16 or other approved models QRA 2, QRA 53 or other approved models

MAT / Hegwein ZNVL (ZT0)

D-52 L5 KV

Z112 K5

8900 l/h

SRB 19000/90

R 1" / 28 mm

MAT

MAT - MK 50

WAN 5 A

R 8"

1400 kg

30 mbar or according to diagram

according to gas pressure

(MAT ignition burner) (Hegwein ignition burner)

7000 - 45000 kW

RPD 100

590 - 3800 kg/h 700 - 4500 m³/h

9500 l/h

SRB 19000/90

R 1"/ 28 mm

MAT

MAT - MK 50

WAN 5 A

R 8"

1450 kg

Technical Data Sheet Duoblock Dual Fuel Burner

RPD 90 & 100 GL-R / GS-R

Page 9

RPD 90 & 100 GL-R / GS-R

Description Dimensions

Operating mode

Fully automatic for ced drau ght dual fuel burner, safety equipment according to EN 267 and EN 676, especially designed for high turn down ratios.

Electric design

Combustion air

Separate combustion air blower with stable and p ulsation-free characterist ics also on appli ances with a high flue gas resistance. The combustion air volume

is divided into a primary and a secondary stream. The flame shape may be adapted by adjustable twist dampers.

Control systems

Monitoring system

Ignition

Direct electric high voltage ignition, 5000 V, by means of an inbuilt ignition burner.

L6 50%

L4 100%

RPD 20 - 60

P1 P2

B1 444

B3 B4 B5W

15°

Stift M

Gewinde Länge K

Bohrungen Kesselplatte

22,5 °

RPD 70 - 100

RPDA1B1B2B3B4B5B6B8D1D2D3D4D5D6D7 G H1H2H3H4 K L1L4

90 1700 75 3 420 375 75 870 890 1800 1750 883 870 675 - 18 810 905 850 1755 1100 30 745 190

100 1700 75 3 420 375 75 870 890 1800 1750 935 922 830 - 18 810 905 850 1755 1100 30 745 190

RPD L5 L6 M P1 P2 P3 P4 R T T1 T2 T3 U V W X Y Z LB C FI F2 F3

90 2585 - 12 1300 1390 742 832 2720 224 310 832 620

28x1,5

8" 494

6x132

10x135

10 - - - - -

100 2585 - 12 1300 1390 742 832 2720 224 310 832 620

28x1,5

8" 494

6x132

10x135

10 - - - - -

set screw M length K

Details of boiler front plate

Page 10

Burner Construction

1 Secondary air pressure switch 2 Ignition gas valve group 4 Inspection glasses 5 Terminal box 6 Gas flow rate control damper 7 Secondary air connection 11 Primary air damper 12 Sleeve 13 Combustion air for ignition burner 14 Flame monitor 15 Gas feed pipes 16 Air guide valve 17 Gas nozzles 18 Nozzle

19 Turbulator 20 Flame tube 21 Burner tube 23 Secondary air control valve 24 Extracting assembly 26 Burner housing 27 Ignition burner 28 Nozzle rod 29 Oil pressure switch 30 Oil flow rate controller 32 Electric actuator

Combustion air connection

The combustion air connecti on (Item 7) may be mounted at intervals of 45° for the RPD 30-60 version and 30° for the RPD 70-90 ver s ion. The burner equipment plate with control block and all valves and instruments will be retained in the vertical position in any case.

13 2 1 14 19 18 20 21 23 26 24 28 27

4 17 16 15

5 6 29,30 7 32

Page 11

Mounting the Burner to the Boiler

The burner plate of the boiler must be fabricated to the specified dimensions. Mount the burner to the boiler with its insulation backing. Apply a layer to graphite or similar lubri cant to the bo lts and tighten by equal amounts. Mixing ignition units extended in length are available for boilers requiring a specifi c installation depth of the burner flame tube.

Refer to the drawing for the mounting dimensions of the burner and air duct and exhaust gas connection, if any.

Boiler lining

The boiler lining must consist of heatresistant materials (temperature resistance >1400°C).

Take care that the burner flame tube is covered by the boiler lining over its full lenght.

The space between the burner flame tube and lining is packed with mineral wool.

Burner mounting inspection

1. Check the mixing ignition unit according to the boiler output.

2. Adjust the pilot burner.

3. Refer to the dimensioned drawing for adjusting the mixing ignitio n unit.

Boiler lining

Burner flange sealing

Mineral wool

Burner

Insulation

Boiler plate

Mounting bracket

Textile compensator

Air duct

Combustion air fan

Baseframe to anti-vibration mounting

Page 12

Combustion Air Fan Drive Modes

1. Direct dr ive

In this concept the motor is coupled directly to the fan impeller. The fan impeller is mounted directly on the motor shaft end. The speeds used are those of the drive motors only. The bearing of the motor shaft must be specifically designed for the fan impeller used.

Recommendation: up to 10 MW output

2. Drive via flexible coupling

The fan impeller is mounted on its own shaft by means of a bea rin g sp ec ific al ly designed for the purpose. The powe r is transmitted from the drive motor via a torsionally flexible coupling. The speeds used are those of the drive motor.

3. V-belt drive

The fan impeller is mounted on its own shaft by means of a bea rin g sp ec ific al ly designed for the purpose. The powe r is transmitted from the drive motor via Vbelts which can provide practically any desired speed.

Air duct and fan

Baseframe: Pre-mount exactly.

Do not prestress for

mounting. Direction of rotation: Check for proper

direction of rotation.

Fans with V-belt drive should be chekked for V-belt tension after about 12 hours of operation and the V-belts retensioned if necessary. If the V-belts are not properly tensioned this will cause slip with resultant lower speed and a considerably reduced service life. Mount the air ducts in a way to ensure an accurate and reliable fixing of the fan. Connect the air duct by mean s of a compensator to avoid transmission of stress. The air ducts are made from 3-4 mm metal sheet.

Page 13

Dimensioned Drawing for RPD Burner 20 - 100

Oil, Gas and Dual-fuel Burners (without external exhaust gas return)

Boilerplate holes

Set screw M

Lenght K

Attention for burners type U

Mixing unit see on separate

sheet

Page 14

Dimensions of RPD Burner 20 - 100 Oil, Gas and Dual-fuel burners (without external exhaust gas return)

*) Note: If longer flame tubes are used, the extended lenght must be

added to the dimensiones G, R, L5 **) D4 = burner tube outside diameter ***) Flange acc. to DIN 2631 for RPD 20 to 70, and acc. to DIN 2633 for RPD 80, 90 and 100

RPDA1B1B2B3B4B5B6B8D1D2D3D4D5D6D7 G H1H2H3H4 K L1 L4L5

**)

100% 50%

MAT

RDG

1250

10 0% *)

530 53 29 90 314 91 560 325 530 500 270 260 210 - 12 250 385 265 650 425 30 465 - 68 780

745 78 19 260 375 70 705 416 830 790 385 371 290 323 17,5 317 620 373 993 650 30 550 700 124 1350

745 78 19 260 375 70 705 416 830 790 423 409 340 367 17,5 442 620 373 993 650 30 550 700 95 1425

950 78 19 315 375 70 760 535 1030 990 470 456 380 410 17,5 370 675 475 1150 740 30 600 770 110 1620

994 78 19 315 375 70 760 622 1080 1040 520 506 420 455 18 312 700 497 1197 825 30 650 735 125 1695

1160 78 19 315 375 75 765 731 1240 1200 640 626 520 565 18 469 780 580 1360 900 30 740 - 170 1995

1350 75 19 315 375 75 765 860 1450 1400 740 710 597 646 18 600 820 675 1495 1000 30 700 - 185 2285

1700 75 3 420 375 75 870 890 1800 1750 883 870 675 - 18 810 905 850 1755 1100 30 745 - 190 2585

100

1700 75 3 420 375 75 870 890 1800 1750 945 922 830 - 18 810 905 850 1755 1100 30 745 - 190 2585

RPD L6 M P1 P2 P3 P4 R S1 S2 T T1 T2 T3 U DN W X Y Z

50% *) ***)

- 10 430 510 236 316 - - - 112 150 240 -

18x1,5

50 190

2x1 43 4x1 20

62 12 580 670 320 410 1265 140 497 160 192 491 346

22x1 ,5

80 248

4x92 5x1 26

50 12 580 670 320 410 1265 140 497 160 192 491 346

22x1 ,5

80 248

4x92 5x1 26

55 12 740 830 416 506 1743 115 595 181 250 530 376

22x1 ,5

125 319

3x1 52 5x1 56

62 12 750 840 470 560 1760 195 622 181 270 555 401

22x1 ,5

125 379

4x1 29 5x1 60

85 12 936 102 6 600 690 2010 270 705 181 365 610 450

28x1 ,5

125 410

5x1 28 7x1 40

92 12 1102 1192 700 790 2320 310 800 187 310 707 495

28x1 ,5

200 489

6x1 25 9x1 28

- 12 1300 1390 742 8 32 2720 240 845 224 310 832 620

28x1 ,5

200 494

6x1 32 10x 135

100

- 12 1300 1390 742 8 32 2720 240 845 224 310 832 620

28x1 ,5

200 494

6x1 32 10x 135

Page 15

Burner scheme Gas train

RPD 30, 40 and 50 GL - R / GS - R

TRD 604 - 72 hr :

The 310, 311,312, 313, 313a pressure switches are approved in dual mode or under the code of "special construction requirements", the solenoid valve RL (182) in the return line is required.

TRD 604 - 24 hr :

The 310, 311, 312, 313, 313a pressure switches are designed in single mode. The solenoid valve RL (182) is built in if the return flow pressure / ring line pressure exeeds 1 bar.

EN :

The 310, 311, 312, 313 pressure switches are designed in single mode. The 313a max. pressure switch is not available. The solenoid valve RL (182) is required.

Electrical heating cartridges for the oil bloc, the nozzle rod and the hoses are used with heavy oil burner versions only.

Always 1x178 und 1x182 electrical connected in-line

100 Burner 120 Secondary air cylinder 125 Primary air damper 141 Ball valve 142 Gas filter 143 Pressure gauge with manual valve 144 Pressure governor 145 Safety shutt-off valve 147 Test burner w. push button valve 148 Safety blow off valve 150 Gas butterfly valve 151 Ignition burner lance 152 Air regulating valve 153 Main gas solenoid valve 154 Safety shutt-off solenoid valve 155 Ignition gas solenoid valve 156 Ignition gas solenoid valve 157 Gas regulating valve 167 Ball valve 177 Pressure gauge with manual valve 178 Oil solenoid valve, feed line(115 V) 179 Hydraulic shut-off valve 180 Nozzle assembly with shut-off valve 181 Solenoid valve, oil circulation 182 Solenoid valve, return line (115 V) 183 Oil hoses 184 Pressure regulator return line 185 Coupling 186 Electrical cartridge heater, oil bloc 187 Pressure regulator feed line 188 Trace heating, oil hoses 189 Trace heating, nozzle rod 310 Air pressure switch 311 Oil pressure switch, return line 312 Oil pressure switch, feed line 313 Gas pressure switch, low 313a Gas pressure switch, high 314 Gas leakage control 349 Mechanical compound controller

Burner scheme TRD 604 - 72 h

gas

oil feed line

ignition electrodes

oil return line

air

primary air

secondary air

ignition gas

Gas train TRD 604 - 72 h

air

secondary

primary

Page 16

Burner scheme Gas train

RPD 60 - 100 GL - R / GS - R

TRD 604 - 72 hr :

The 310, 311,312, 313, 313a pressure switches are approved in dual mode or under the code of "special construction requirements", the second solenoid valve RL (182) in the return line is required.

TRD 604 - 24 hr :

The 310, 311, 312, 313, 313a pressure switches are designed in single mode. The second solenoid valve RL (182) is built in if the return flow pressure / ring line pressure exeeds 1 bar.

EN :

The 310, 311, 312, 313 pressure switches are designed in single mode. The 313a max. pressure switch is not available. Both solenoid valves RL (182) are required.

Electrical heating cartridges for the oil bloc, the nozzle rod and the hoses are used with heavy oil burner versions only.

Always 1x178 und 1x182 electrical connected in-line

100 Burner 120 Secondary air cylinder 125 Primary air damper 141 Ball valve 142 Gas filter 143 Pressure gauge with manual valve 144 Pressure governor 145 Safety shutt-off valve 147 Test burner w. push button valve 148 Safety blow off valve 150 Gas butterfly valve 151 Ignition burner lance 152 Air regulating valve 153 Main gas solenoid valve 154 Safety shutt-off solenoid valve 155 Ignition gas solenoid valve 156 Ignition gas solenoid valve 157 Gas regulating valve 167 Ball valve 177 Pressure gauge with manual valve 178 Oil solenoid valve, feed line (115 V) 179 Hydraulic shut-off valve 181 Solenoid valve, oil circulation 182 Solenoid valve, return line (115 V9 183 Oil hoses 184 Pressure regulator return line 185 Coupling 186 Electrical cartridge heater, oil bloc 187 Pressure regulator feed line 188 Trace heating, oil hoses 189 Trace heating, nozzle rod 310 Air pressure switch 311 Oil pressure switch, return line 312 Oil pressure switch, feed line 313 Gas pressure switch, low 313a Gas pressure switch, high 314 Gas leakage control 349 Mechanical compound controller

Burner scheme TRD 604 - 72 h

gas

oil feed line

ignition electrodes

oil return line

air

primary air

secondary air

ignition gas

Gas train TRD 604 - 72 h

air

secondary

primary

Page 17

Hydraulic Scheme RPD 30 -50

Oil Control Block and Nozzle Rod DG 75

Oil circuit at burner stand by (Zirkulation)

Oil circuit at burner pre-purge

Oil circuit at burner operation

1. Oil pressure pump

2. Safety valve

3. Oil filter

4. Pressure gauge (feed line)

5. Oil regulating valve

6. Manual valve (for bleeding)

7. Circulating valve

9. Hydraulic cylinder for ball valves

10. Oil regulating valve, return line

11. Pressure gauge (return line)

12. Ball valve

13. Inner nozzle oil line assembly

14. Solenoid valves

15. Return nozzle

16. Pressure hoses

Page 18

Hydraulic Scheme RPD 30 -100

Oil Control Block and Nozzle Rod MAT

14 14

1616

Oil circuit at burner stand by (Zirkulation)

Oil circuit at burner operation

1. Oil pressure pump

2. Safety valve

3. Oil filter

4. Pressure gauge (feed line)

5. Oil regulating valve

6. Manual valve (for bleeding)

7. Circulating valve

9. Hydraulic cylinder for ball valves

10. Oil regulating valve, return line

11. Pressure gauge (return line)

12. Ball valve

13. Inner nozzle oil line assembly

14. Solenoid valves

15. Return nozzle

16. Pressure hoses

17. Non-return valves

Page 19

1. oil solenoid valve circulation

2. oil regulating valve return flow

3. oil regulating valve bloc inlet pressure

4. regulating needle

5. spring

6. washer

7. shaft

8. surclip

9. O- ring seal N. 19

10. bush gland

11. gasket

12. washer

13. surclip

14. spring

15. washer

16. surclip

17. regulating needle

18. spring

19. washer

20. shaft

21. gasket

22. bush gland

29. shaft

30. piston

31. gasket

32. lock washer

33. nut M8

34. spring

35. spring cover

36. cover plate

37. aluminum washer

38. valve flange

39. double blocking valve

40. outer shaft ring

41. washer

42. fixing ring

43. valve cover

44. O ring gasket

45. cover

46. block body

47. nut M8

Oil Control Block

Page 20

Mounting Position Leak Test Ignition Gas Connection Ignition Burner Type ZT0

Mounting position

Gas pressure regulator s and valves can be mounted in vertical lines in any position within the 360° range. In horizontal lines they must not be mounted overhead and only 180° in the upper se cto r. The ball valve and filter can be mou nted in any desired position. Take care that the housing does not m ake c ont act w ith the wall and is clear by minimum 20 mm. Do not use the spring bolt of the regulator and the solenoid elements of the valves as levers.

Leak test

Check the screwed joints and flanged connections for absence of leaks. The leak test of the joints should be made under pressure using only foaming agents approved by DVGW and not causing corrosion.

Electrical wiring of gas valves

Check that the data given on the nameplate of the gas valves agree with the mains voltage. Open the terminal box of the valve. Feed the connection cable through the screwed union (condui t thr ead Pg 13 .5) and connect the terminals marked accordingly. L = phase N = zero conductor = protective conductor (green-yellow)

Disconnectable joint

An easy-to-disconnect joint with flat sealing (e.g. compensator) should be provided to allow the boiler door to be swivelled out if required for maintenance work on the boiler (furnace chamber). Th is compensator should also be designed to accommodate the axial or lateral expansion and absorb vibrations.

Ignition gas connection

An ignition burner is used to ignite the main gas flame. The ignition gas line is branched out of the gas control group between the two gas valves and installed to the ignit ion bu rner on the s hortes t possible way. In the case of oil and dual-fuel burners the burner is ignited with propane supplied through a separate R „ propane connection. The ignition gas flow rate may be adjusted on the volumetric flow control valve of the ignition gas valve or directl y on the ign ition gas burner. The required gas pressure for the ignition gas burner is 50150 mbar . It is ad vis ab le to ins t all a gas pressure regulator upstream of the ignition gas burner . Th e air pres sure for the ignition gas burner should be between 10 and 30 mbar. The boi ler back pressure shall not be taken into account. The air pressure should be adjusted in accordance with the gas pressure to ensure an undelayed ignition and a good flame pat tern.

1 Transformer unit with bui lt-i n

ignition transformer 2 Electrical angular plug connector 3 Gas connection, may be

connected on either side right and

left with gas test socket 4 Air connection, mounted to

transformer unit 5 Air test socket 6 Igniter tube, mounted to air flange

7Spacer ring 8 Ignition electrode connection rods 9 Gas tube 10 Ignition electrode connection rods 11 Gas nozzle for natural gas or

propane

12 Mixing chamber

* The outside diameter will be 50 mm for

tube lengths above 4000 mm and for all high-grade steel tubes.

Mounting f lange View A

Gas RP1/2 normally left

Air Rp1

Ignition Burner Type ZT0

Page 21

Ignition Burner Type ZT0

Technical Data

Construction according to sectional drawing

The igniter consists mainly of the transformer unit (Item 1) housing the ignition transformer , the ignit er tube with a ir and mounting flange (Item 6 ), a gas tub e (9) with nozzle (11) and the electrode carrier ring (10). The igniter tube with the Rp1 air connection is bolted to the transformer unit. After the 4 bolts (Item

4) have been unscrewed it may be removed or turned by 90° if required by the position of the air connection. When turning the tubes care must be taken not to change the position of the inner supporting rings and rods because this might lead to operational trouble. The gas supply may be connected either to the left-hand or right-hand opening. The opening not used is closed with a screw plug which al so car ries the screw-in gas test socket (3). The electrode support ring (Item 10) is mounted to the end of the gas tube.

The ionization electrode and ignition electrode are extended with conn ec tin g rods (Item 8). These rods are installed through the bottom of the transformer housing in 2 ceramic insulators and carried by intermediate supporting rings (Item 7) spaced at 300 mm.

Flame moni tor

An ionization electrode is provided for flame monitoring. The flame signal is generated by d.c. current which due to the ionization effect and the rectifier effect of the flame is caused to flow from the igniter tube earth via the flame to the ionization electrode and via the connecting rod to the amplifier in the automatic furnace controller. The ionization electrode and ignition electro des ar e adjusted in accordance with the dra wing.

When installing new electrodes these must be bent, cut to len gth and adjusted as required. The internal resistance of the ionization system amounts to some megohms. Such a high resistance ensures a good insulating capacity of the electrodes and connecting rods. In a dust-laden combustion air environment it is therefore important to clean t he ins ulators a t shorter intervals. Humidity should be kept out. See also electrical function. The ceramic insulator of the ionization electrode must not be allowed to heat up above 500 °C because this could lead to shutdown on tro ubl e. Therefore, a minimum air flow rate (10-20 % of the full-load rate) should be allowed to flow if this temperature is likely to be reached by radiation or convection with the furnace chamber in hot condition and the burner flame turned off.

Technical data of ignition gas burner type ZT0

Fuel gases according to G 260 Flame power max. 120 kW Flame length max. 600 mm Gas connection Rp 1/2 right or left Air connection Rp 1, may be turned by 4x90° Air flow rate max. 50 m³/h Air index 0.3-0.5; remaining air rate must be available from furnace chamber Max. ambient temperature 500°C in tube; if temperature is higher, keep combustion air

connected partly as cooling air; 0°C to +60°C in transformer unit

Transformer unit

Connection voltage 230 V, 50 Hz Connector type plug connector Power input ignition transformer 100 VA, 20% duty cycle (with thermal winding shield)

ignition 5 kV (2-3 seconds via automatic furnace controller) Ambient temperature 0°C to +60°C Degree of protection IP 54

Electrical connection

Cl. 1 (Mp) Cl. 8 (Ph) ignition transfer, primary Use shielded cable Z 912 F 00 for flame feedback. Cl. 10 ionization signal NOTE: The shield must not make contact with earth.

Page 22

Ignition Burner Type ZT0

Gas Pressure Adjustment Parts List

Gas pressure adjustment

In standard version the igniters are suitable for a working range 50-150 mbar. If a higher gas pressure is required in the customer's order, the two threaded gas inlet connections will be fitted with restrictors by the manufacturer already. The igniter will in this way be adjusted to the pressure above 150 mbar. If the higher inlet pressu re is recogniz ed at a later stage only, a restriction to maximum 150 mbar can also be achieved by means of a ball valve, for example.

Characteristic line Gas type Nozzle holes Flame length

P Propane 1x2,5 + 6x1,0 approx. 600 mm M Natural gas 1x4,0 + 6x1,3 approx. 500 mm N City gas 1x5,0 + 8x2,3 approx. 500 mm

Parts list

Item. Qty. Description Part No. Material

1 1 Transformer unit Z 112 K 5 Housing of GAL 2 1 Right-angle plug with 2 unions A 5 Z 1 10-pole, max. 2.5 3 1 Gas test socket Z 138 Z 2 Ms 58 4 4 Hexagon socket head screw W 826 F 10 5 1 Air test socket Z 138 Z 1 Ms 58 6 1 Igniter tube with rolled-in mixing chamber and mounting

flange with Rp1 air inlet thread

Z 1050 Z...** GAL / steel

7 * Intermediate supporting ring with 2 ceramic insulators Z

545 F11

Z 960 K 4 St VII 23

8 2 Connecting rods Z 781 F...** Zinc-plated steel 9 1 Gas tube Z 521 F...** St 35

10 1 Electrode carrier ring Z 960 K 13 St VII 23

11 1 Gas nozzle Natural gas

Propane City gas

Z 330 F 4013 Z 330 F 2510 Z 985 F 1

High-grade steel 1. 4104 High-grade steel 1. 4104 High-grade steel 1. 4104

12 - Mixing chamber with mixing ring Included in

Item 6

High-grade steel, heat-resistant

* Quantity depends on pipe length: 3 intermediate rings per metre of tube length. ** Additional data according to type (tube length).

Page 23

Ignition Burner Settings Electrode Carrier Ring

Front view

Side view

110 mm for natural gas

90 mm for propane

Top view

Natural gas

Propane

Electrodes Z 707 F 3

Ceramic Z 545 F 11

Ring W 715F 101 Bush Z 789F 10

Preset amount of bend and adjustment Cut ionization electrode to length according to gas type.

Page 24

Ignition Gas Solenoid Valve

Type MVD 505 / 5 single-stage

Technical data:

Nominal bore: R1/2“ Max. operating pressure: 500 mbar Opening time: < 1 sec Closing time : < 1 sec Ambient temperature:-15°C to +60°C Mounting position: solenoid in upright

position vertical to horizontal

Voltage/frequency: (AC) 230 V

(+10% -15%) Duty factor: 100% CD Degree of protection: IP 54, IP 65 Power rating: 15 VA

Main flow rate adjuster type series MVD

Unscrew the prot ective cap a nd remove the lock nut to allow the main flow rate to be adjusted. The main flow rate adjuster is supplied ex works in fully opened position. Turning clockwise will reduce the gas flow rate. Turning counterclockwise will increase the gas flow rate. After having adjusted the flame control on the gas burner make sure to tighten the lock nut again. Screw on the protective cap again.

Installation

When installing the valve in the pipeline take care to observe the arrow on the valve housing and the required mounting position. For screwing the pipeline into the valve housing do not use the magnet as a lever but apply a suitable tool against the valve housing. After installati on ma ke a test for absence of leaks and proper operation.

Solenoid replacement type series MV, MVD

Disconnect the electrical termina ls ; remove the screw cap; lift off the solenoid. For install ation proc eed in reve rse order.

Electrical connection

Feed in the cable through cable union (conduit thread Pg 11). Make the electrical connection by me ans of the screw terminals in the termi nal bo x of the sole noid housing. Take care to observe the connection diagram.

1 Cable union 2 Electric terminal box 3 Solenoid 4Housing 5Screen 6 Valve seat 7 Connector for

earthing contact K01/1

8 Valve disk 9 Mud guard 10 Closing compression spring 11 Anchor 12 Main flow rate adjuster 13 Lock nut 14 Protective cap

Protective cap

Not acceptable

Page 25

Oil Connection Fuel Oil Supply

Oil connection

For the installation of a furnace system care should be taken to observe the applicable rules and regulations. When installing an oil burner be sure to follow the recommendations outlined for oilfired furnace systems (DIN 4787, DIN 51603 Parts 1&2, TRD 411). DIN 4736 Parts 1 &2 describes the safety requirements applicable to the oil supply systems of oil burners. DIN 4755 Part "Oil furnaces in heating installations (safety requirements)" outlines the safety recommendations for oil furn ac e systems of steam boilers. The installer has the duty to inform himself of the regulations applic able to gas and oil furnace systems.

Fuel oil supply

Complete oil feeding groups are available for the supply of the furnace systems with fuel oil. A fuel oil supply unit may consist of ball stop valve, suction filter , pressure gauge, pump with coupling and threephase rnotor. All units are all finished ready for connection and mounted with anti-vibration elements on an oil collecting tray. The oil supply lines must be slelected in accordance with the technical instruction sheets and installed in line with the applicable specifications. The total pipeline length is understood to be the length of all horizontal and vertical lines and bends. The maximum permissible vacuum at the suction port of the pump may be -0.6 bar. A higher vacuum will lead to the escaps of gas resulting in an unsteady delivery and damage to the pump. All connections must be tightened to avoid leaks. The sealing rings used should be of copper, aluminium or plastic. In no case should hemp or similar sealing material be used. The pipelines must be cleaned before they are connected to the pump.

Ring line operation

lf several burners and storage t anks are installed in a system o r if t here is a large distance between the burner and the storage tank, a ring line system with gas-air separater will be needed for supplying the burners. NOTE: In case of pressurized oil feed, the suction press ure of the p ump shoul d not exceed 5 bar. All lines must be fixedly installe d, welded to oil-tight s tandards or connected with oil-tight unions or flanges. Flexible tubes are allowed only as connecting pieces between the fixed line and the burner . The flexi ble tubes should be installed properly (in hanging position) and free of sharp bends.

For the installation of the flexible tubes take care these do not get twisted. They should not be subject to torsional stress neither at the stage of installation nor during subsequent movernents.

Oil pressure pump filling

Prior to initial oparation make sure to fill the oil pressure pump and oil feed line with oil to prevent the pump from dry running and getting seized.

Oil filter

lt is recommended to install a filter directly upstream of the pump to separate dirt particles contained in the oil or any other foreign matter produced during installat ion. When a fuel oil uni t is mounted this will be fitted with an oil filter already.

Starting the oil pump

- Make sure all stop valves are open.

- Check the pump for direction of rotation.

- The safety overflow valve in the pump is preset at 40 bar and may be readjusted by duly authorized specialists only.

Pressure atomizer

The oil throughput rate of the nozzle and thus the burner output is controlled by an oil regulator valve installed in the return line and coupled to the actuator and compound controller.

The oil throughput rates and oil flow pressures downstre am of the nozzle ro d must be set according to the applicable nozzle characteristic. As the oil control valve is closed or opened the oil through put rate of th e n ozzle will be increased or reduced, respectively. The oil pressure up stre am of th e nozz le rod must be set at 28 bar to 30 bar. Depending on the version this can be can be adjusted either on the fuel oil station or on the oil control block of the burner.

Page 26

Oil Connection Fuel Oil Supply

Oil connection

For the installation of a furnace system care should be taken to observe the applicable rules and regulations. When installing an oil burner be sure to follow the recommendations outlined for oilfired furnace systems (DIN 4787, DIN 51603 Parts 1&2, TRD 411). DIN 4736 Parts 1&2 describes the safety requirements applicable to the oil supply systems of oil burners. DIN 4755 Part „Oil furnaces in heating installations (safety requirements)“ outlines the safety recommendations for oil furn ac e systems of steam boilers. The installer has the duty to inform himself of the regulations applic able to gas and oil furnace systems.

Fuel oil supply

The operational reliability of a burner system depends greatly on the oil supply conditions. Oil supply lines must be determined according to the technical instruction sheets and inst a lled b y strict adhe rence to the applicable regulations. All joints must be mounted with due care to ensure they are absolute ly tight. The sealing rings used must be made from copper, aluminium or plastic. In no case should hemp or a similar material be used. Make sure to remove any dirt from the pipelines before mounti ng them to the pump.

Normally, a ring pipe system will be used. In addition to the electri c tracing l ines, a ring pipe system for heavy oil installations comprises the following major components:

oil delivery pump, oil filter , gas-air vent, and pressure control valves.

The electric tracing lines and the tank heaters will ensure that th e fuel oil to be delivered is kept in a pumpable state. An oil filter must be installed in the feed line upstream of each burner to avoid that dirt particles and other impurities possibly left behind after pipe installation cannot damage the solenoid and pressure control valves. Steam trac ing or hot-wa ter trac ing systems can be used instead of the electric tracing lines.

T o av oid burner troub le due to entrain ed air, a gas-air vent must be provided at the uppermost position of the ring pipe system.

The ring pipe pressure must be controlled in dependence of the fuel oil temperature. As can be seen from the chart below, the static pressure of the oil at 130°C must be minimum 3 bar, for example.

Oil pressure in dependence of operating temperature

The fuel oil withdrawn from the ring pipe or gas-air vent is pumped to an oil preheater and on to the b urner by means of a high-pressure pump. The return oil from the burner is fed into the ring pipe in any case and not directly into the tank.

Oil pressure pump filling

Prior to initial operation make sure to fill the oil pressure pump and oil feed line with oil to prevent the pump from dry running and getting seized.

Oil filter

It is recommended to install a filter directly upstream of the pump to separate dirt particles contained in the oil or any other foreign matter produced during installat ion. When a fuel oil uni t is mounted this will be fitted with an oil filter already.

Starting the oil pump

- Make sure all stop valves are open.

- Check the pump for direction of rotation.

- The safety overflow valve in the pump is preset at 40 bar and may be readjusted by duly authorized specialists only.

Pressure atomizer

The oil throughput rate of the nozzle and thus the burner output is controlled by an oil regulator valve installed in the return line and coupled to the actuator.

100 110 120 130 140 150 160

Temperatur °C

Druck bar

Temperature °C

Pressure bar

Page 27

Medium pressure screw pumps Installation

Commissioning Maintenance

Medium pressure screw pumps

General

Screw pumps are rotating positive displacement pumps with strong suction, which can be used with self-lubricating agents.

1. Application guidelines

1.1 Shaft seals for normal versions

1.2 Pressure relief valve

This valve protects the pump against overloading and should not be used as a pressure control valve. This is absolutely necessary if a shut-off device is fitted in the pressure pipe. Standard pressure setting unless otherwise required at the time of ordering. Low pressure pumps (type N) approx. 6 bar, medium pressure pumps (type M) approx. 40 bar or 10% above the specified operating pressure, as with Ctypes. By turning the adjustment sc rew in a clockwise direction = pressure increase.

2. Installation

2.1

Clean any plant parts (ensure no dirt or loose particles in the pipes) and fi t pipes (flange) without any stress. Observe direction of flow as well as any possible heat expansion of the pipes.

2.2

Ensure stress-free fitti ng of th e pump or base frame.

2.3 Coupling

Motor and pump shafts must be aligned. Axial play between the Coupling halves approx. 1.5 mm. It should be possible to turn the whole unit of pump shaft-Coupling-Motor shaft by hand. Installation of the coupling halves: Sliding on (tapping not permitted) in heated condition (min. 100°C); Press p lastic couplings home in cold condition.

2.4

Check direction of rotation of the motor and the pumps a nd pro tect the moto r by means of a motor protection switch.

3. Commissioning

3.1

The pump must not be allowed to run dry! Before initial commissioning of the pump fill the pump with operating medium and open suction and shut-off devices on the pressure side. The medium must be free from solids.

3.2

With hot medium (above 100°C) heat the pump before s t art ing (pump heating facility). ATTENTION! The medium in the pump and pipes must be able to expand freely during heating (development of unauthorized pressures with enclosed medium).

3.3

Viscous mediu m, whic h can only be pumped after heating, must be heated first in the pump and pipes (pump heating as well as secondary heating for pipes). ATTENTION! Heat expansion of the medium (see above). When pumping heavy heating oil it is essential that cold starting of the pump is avoided (use pu mp heating prov ided), as this could also damage the shaft seal.

3.4

Vent the pressure pipe during initial starting of the pump.

3.5

Switching off the pump: Residual static pressure in the pressure pipe must no exceed that of the permissible supply pressure. If necessary, de-pressurize the pump through the non-return valve, as this pressure pressurizes the shaft seal which in turn could damage the seal. The same applies to parallel operation of several pumps.

4. Maintenance

Special maintenance of the screw pumps is not required. In case of damage to the pump of the inst allation it is possible that medium will leak out. In order to avoid subsequent damage it is recommended that respective warning devices are fitted.

Type of seal Max. supply

pressure

Max. Temperature

Rotary shaft 0,5 bar 80°C Packing rings 3 bar 150°C Axial face seal 5 bar 150°C

Page 28

Medium pressure screw pumps Technical specifications

Function Versions

Technical specifications

Function

Screw pumps have three rotating spindles, of which the main spindle supplies the hydraulic power and the auxiliary spindles, which run free, have only a rotating function. The two-speed main and auxiliary spindles crea te sup pl y chambers within the enclosed housing, which move constantly from the suction to the pressure side. Due to this principle the screw pump s ca n also o perate under high pressures, revolutions and provide strong suction, they are extremely quiet and almost pulse-free.

Safety valve

All types of medium pressure pumps can be supplied on request with or without a spring-loaded pressure control valve. The valve is installed to protect the pump and/or installation against excess pressure, but cannot be used solely as a control valve.

Materials

Supply spindles Nitrided steel Housing Grey cast iron (M55 to M210) Nodular graphite

iron Operating housing Al-Si alloy * Cover plate Al-Si alloy *

* Guarantees the best emergency

running characteristics and long service life

Flow rate Approx. 3 - 420 l/min Operating pressure Max. 40 bar Supply pressure See under versions Operating temp. See under versions Viscosity 1.0 E (6 cSt) to

100 E (758 cSt) and greater

Direction of rotation Right, viewed from

drive

Heating Supplied on request

1. Main spindle

2. Auxiliary spindle

3. Enclosed housing

4. Pump housing

5. Safety valve (adjust a ble )

6. Main spindle bearing

7. Seal

8. Compensating bore

9. Compensating piston S Suction chamber D Pressure chamber

The axial forces acting on the feed screws are balanced (compensated) by the compensating piston (9) and compensating bores (8).

Versions

Medium pressure sc rew pump s, as shown on the follo wing p ages, a re suppli ed in various constructions. Depending on the application, the following types of seal are available:

Rotary shaft sealing ri ngs

Normal packing and rotary shaft seal

Temperature: Max. 150 °C (above 150°C on request) Supply pressure: Max. 5 bar (above 5 bar on request)

Temperature: Max. 80°C Supply pressure: Max. 0.5 bar

Axial face seal

Page 29

Burner Pump Assembly Electrical Connection

Burner pump assembly

The installation material and all electrical connections and earthing points must be in accordance with the VDE 0116 specifications and the local regulations. The electrica l connection o f the burner must be made as shown in the circuit diagram att ached hereto. The electrical control lines are installed through the screwed cable joints and connected to the numbered terminal strip in accordance with the circuit diagram. Control boxes related to the burner must also be connected in accordance with the enclosed circuit diagram and VDE 0116 and taking into account the local regulations. After the electrical connections have been completed a check must be made for the correct wiring of all items of the equipment. Also the direction of rotation of the air fan and of the pump should be checke d.

1 Electrical terminal box 2 Plug connector 3Terminal strip 4 Cable bushings

Electrical connection

1Stop valve 2 Pressure/vacuum gauge 3 Ball valve 4 Oil pressure pump

(volumetric) 5Drip tray 6 Oil filter 7 Ball valve 8 Flange connection 9 Pump bracket 10 Pump-end coupling 11 Motor-end coupling 12 Electric motor

Page 30

Return Nozzle Rod DG 75

Functional description Pre-flushing

The oil delivered by the burner pump will enter the feed pipe (Item 2) via the connection block (Item 1). Then it flows through the feed pipe to the closing taper plug of the regulating piston (Item

4). The plug is permanently pressed against the nozzle head (Item 7) by a cylindrical pressure spring (Item 5) so that the feed pipe is kept in closed position. At the same time, pressure is applied to the connecting rod (Item 8) by a spring (Item 6) so that the valve needle (Item 12) is pressed against the return opening of the nozzle head (Item 7), thus keeping the latter in closed position. In this position the oi l may only enter the return pipe (Item 9) through the o pened flushing hole (Item 13 ) an d wi ll return to the gas-air separator and finally to the fuel tank. This will give an effect ive flush up to the nozzle.

Operating function

After the air pre-flushing period, an electromagnet will be operated and apply a tensile force via an arm (Item

10) to the connecting rod (Item 8). As the valve needle and the regulating piston are connected to one another, the feed pipe and return pipe will be opened at the same time so that the oil can flow to the nozzle through the hole of the nozzle head. At the same time the regulating piston (Item 4) will shut off the flushing hole (Item 13) to the retur n pipe. T his causes the oil to be forced to the nozzle with part of the oil flowing back through the return opening of the nozzle (Item 11) and the nozzle rod. The return oil flow rate is controlled in dependence of the pressure by means of an output pressure regulating valve i n accordance wi th the required load. When the burner is stopped the solenoid actuator will be turned off so that through the action of the pressure springs in the feed and return pipes the valve needle and the regulating piston will shut off the return pipe and feed pipe, respectively. For the adjustment of the transmission arm (Item 10) it should be ensured that the solenoid actuator (Item 14) is deenergized. Care sho uld also be tak en to avoid any mechanical loads. Pull out

the anchor (Item 15) to the stop, unscrew the lock nut (Item 16) and turn the anchor (Item 15). When the solenoid actuator is de-energized there should be a noticeable backlash in the transmission linkage. When operated electrically, the solenoid actuator should produce and audible noise when making contact with the mechanical stop. The valve needle (Item 12) must be operated over its full travel of 4 mm. Tighten the lock nut (Item 16).

Lift

Flushing nozzle rod DG-75 (complete)

Description of items

1. Connection block

2. Feed pipe

3. Rod block

4. Regulating piston

5. Feed pressure spring

6. Return pressure spring

7. Nozzle head

8. Connecting rod

9. Return pipe

10. Arm

11. Return feed

12. Valve needle

13. Flushing hole

Transmission arm

Mount for arm

Feed Return

Page 31

Return Nozzle Rod MAT

Functional description

The oil delivered by the burner pump will enter the feed pipe (9) via the connection block (10). Then it flows through t he feed pipe (9) at the pre-s et pressure directly to the return nozzle. Part of the oil delivered will be returned through the return flow pipe (6) via the return flow hole of the nozzle.

The return flow rate is controlled according to the required output using an output pressure control valve. Approved shut-off valves are installed directly upstream of the inlet to the nozzle rod in the oil feed and oil return lines.

1. Union nut

2. Nozzle plate

3. Intermediate plate

4. Swirl chamber

5. Nozzle rod

6. Return pipe

7. Feed flow

8. Return flow

9. Feed pipe

10. Connection block

Page 32

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5899

Oil [kg/h]

2 alpha [°]

p return [bar]

T est cond ition s:

Page 33

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5902

Oil [kg/h]

2 alpha [°]

p return [bar]

T est cond ition s:

Page 34

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5913

Oil [kg/h]

2 alpha [°]

p return [bar]

T est cond ition s:

Page 35

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5924

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 36

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5946

Oil [kg/h]

2 alpha [°]

p return [bar]

T est cond ition s:

Page 37

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5957

145.513.5968

Oil [kg/h]

2 alpha [°]

p return [bar]

T est cond ition s:

Page 38

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5979

Oil [kg/h]

2 alpha [°]

p return [bar]

T est cond ition s:

Page 39

Throughput Rate Charakteristics Light Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.6007

145.513.5991

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 40

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5899

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 41

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5902

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 42

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5913

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 43

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 27

Article-No.: 145.513.5924

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 44

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5946

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 45

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5957,

145.513.5968

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 46

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5980

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 47

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5979

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 48

Throughput Rate Charakteristics Heavy Fuel Oil

Return Nozzle MK 50

Article-No.: 145.513.5991

145.513.6007

Oil [kg/h]

2 alpha [°]

p return [bar]

Test conditions:

Page 49

Dimensions of the Mixing Unit (standard versions)

RPD 30 - RPD 80

Page 50

Draw-out and Swing Mechanism

Burner Settings

Draw-out and swing mechanism

The duobloc burners type RPD are equipped with a draw-out and swing mechanism. This makes it possible to pull out and swing away the complete central tube for maintenance access to the mixing head and for adjusting the mixing and ignition units. Prior to this, the fastening bolts of the central tube must be unscrewed. The baseplate of the cen tral tub e carries t he ignition burner, flame detector, nozzle rod assembly (only for oil and dual-fuel burners) and primary air connection. After the central tube has been remo-

ved, the air damper in the burner housing will also be accessible.

NOTE: Before removing and swinging away the central tube take care to mount the draw-out and swing mechanism, discon nect the electric plug connectors of the flame detector and ignition bu rner, remove th e primary air connection and discon nect the oil hoses (in oil and dual-fuel burners) with the quick-action couplings provided for this purpose.

Burner head adjustments

Burner combustion head adjustments

In order to enable service work on the burner combustion head and for adjustments of the ignition system the complete burner insert ca n be removed (see burner hinge arrangement). In case of component replacements or service work on the components of the burner head the correct position of the burner head components have to checked and if necessary the appropriate adjustments have to be carried out. The correct measurem ents can be seen in the burner dimensional sheet . The ignition electrodes must be set according to the dimensions shown in the diagramm. As the spray pattern of the oil nozzle depend on nozzle size the given dimensions can only be approximations. It may be necessary for the commissioning engineer to alter the base settings to achieve the best start performance. The distance between nozzle tip and turbulator face depends on the nozzle spray pattern and the size of the turbulat or core hole. The distance has to be adjusted by the commissioning engineer so that the oil cone will impinge on the turbulator. The works setting of the burner head is carried out as shown in the dimensional sheet. In the base setting the nozzle face is positioned flush with the turbulator inner hole i.e. setting "0". It is recommended to note the distance between nozzle rod positioning bush and the end of the protruding nozzle rod as reference position.

Burner combustion head

1 Burner tube 2 Flame tube 3 Cylinder for air stabiliz ati on 4 Ignition Burner 5 Turbulator 6 Nozzle 7 Primary air duct 8 Gas nozzle 9 Gas lances

Page 51

Air Flow Adjustment Oil Flow and Gas Rate Adjustment

Air adjustment

Check that the air swirler setting is in accordance with the furnace/ combustion chamber geometry and re-set if required. In order to ensure uniform distribution, close the air swirler at the air pipe entry against air inlet. The air cur ve of the compound con troller is factor y-set so that the air cylinder is closed at minimum settings and open at maximum settings. The combustion air ratio (sec ondary air) to the fuel can be obtained over the whole of the outp ut rang e by turning the screws, which is then checked by measuring the exhaust. Before the compound controller screws can be adjusted, the lock nuts on the front face and underside of the compound controller must be loosened. Setting of the primary ai r is a lso c arrie d o ut via a cam disk and it can be set accurately by adjusting the threaded studs as required. With a large control range the minimum combustion output is set by means of the primary air.

During adjustment care must be exercised to ensure that over the whole of the control range the air pressure at the central pipe (primary side) is 1.5 - 2 mbar higher than the combustion chamber pressure.

Oil adjustment

For taking into operation, the oil control block with flow control valve in the return line will be preset. The pump pressure is set at approx. 28 bar and the pressure upstream of the control valve at approx. 5 to 18 bar. After loosening of the lock screws of the socketheaded studs and sliding ball, the control curve is adjusted over the whole control range by m eans of the cam disk, after which setting is then locked with the lock screws.

Heavy fuel oil

Heavy fuel oils must generally be heated up. On the one hand, this is performed in the fuel oil storage tank to keep the oil in a pumpable state because the temperature must be above the se ttin g point. Further preheating is required in the service tank, fluid preheater or electric preheater to ensure the heavy fuel oil can be properly atomized and burns

readily. The level of preheating depends on the viscosity of the fuel oil and can be determined from the viscosity-temperature diagram. The atomizing viscosity is at 12 to 15 cSt.

Gas adjustment

The gas damper is connected to the mechanical compound controller by means of a transmission arm. The gas cam of the compound controller is factory-set so that the gas damper is closed in its minimum position and open in its maximum position. The minimum and maximum positions and the intermediate positions of the gas damper are also adjusted with the electronic compound controller . The gas pressure must be corrected by means of the gas pressure controller if necessary. The setting must be checked by making a combustion analysis.

Spindleflame

Long flame

Average length flame

Short flame

Air swirler position

Flame formation

POS 1

Air swirler angle Pressure loss

0 - 20° 30 mbar

POS 2

Air swirler angle Pressure loss

20 - 40° 38 mbar

POS 3

Air swirler angle Pressure loss

40 - 55° 45 mbar

POS 4

Air swirler angle Pressure loss

55 - 70° 55 mbar

Page 52

Mechanical Compound Controller

1 Fuel-air compound cont roll er

mounting bracket

2 Secondary air damper control lin-

kage 3 Primary air control arm 4 Primary air control linkage 5 Primary air angular control arm 6 Spring-loaded sliding block for

gas control 7 Hexagon socket head screw with

pressed-in sliding ball (locked by

means of hexagon socket head

screws on end face of cam wheel) 8 Spring-loaded sliding block for

secondary combustion air 9 Cam disk on drive shaft 10 Drive shaft 11 Spring-loaded sliding block for pri-

mary air 12 Spring-loaded sliding block for oil

flow rate control 13 Transmission rod fo r gas flow rate

control damper 14 Actuator with disconnecting unit

for manual operation 15 Hand wheel for manual adjust-

ment of mechanical compound

controller

16 Return flow connection (only

heavy oil) 17 Feed line hose connector 18 Solenoid stop valve 20 Pressure gauge stop valve 21 Oil pump pressure gauge 22 Oil feed connection from burner

pump 23 Oil pressure switch in fee d line fo r

lack-of-oil monitoring 24 Oil return flow connection 25 Oil pressure switch in return line

for oil overp ressure monitoring 26 Limit switch for oil and gas opera-

tion 27 Oil flow rate control linkage 28 Bypass change-over valve (f lus-

hing valve) 29 Pump pressure adjuster for built-

in primary pr essure controller 30 Bypass solenoid valve (flushing

valve) 31 Return pressure gauge (only

heavy oil)

NOTE: For heavy oil operation, the oil control block and oil flow rate controller are equipped with electric heaters.

Page 53

Pressure Setting

Oil pump pressure setting

Before commissioning the pum p and oil pipes must be primed and vented.

1. Pump pressure

- 28 to 30 bar for light fuel oil

- 30 to 32 bar for heavy fuel oil So as to protect the pump against excess pressures, the oil pressure control valves of the high pressure pump have been factory set to 40 bar. The effective pump pre ssure is s et an d ad justed at the burner control bl ock or at the pressure control valve.

2. Pressure setting at the control valve (loop feeder pipe) at the burner pipe pressure

Light fuel oil setting

Loop feeder pipe pressure 1,2 - 1,6 bar

Heavy fuel oil setting

In order to avoid evaporation of the water in the fuel oil, the pressure in the loop feeder pipe must be at least

-see table:

Pressure control valve

In the piston-type pressure control valve, a pisto n (1) movably arranged in a cylinder is pressed against the valve needle (3) by a spring (2). As the pressure on the side of the valve needle rises above the spring pressure, the piston will be lif ted a nd the o il cau sed to flow over to the pressureless side. For the installat ion of overflow valves of this type the following general information should be observed: The spring side (spring can be seen from outside) must in any case be chosen to be the return side, i.e. the pressureless side. Consequen tly, the direction of overflow is from the pressurized side to the pressureless spring side. Any counterpressure on the return side must thus be added to the s elected spring pressure setting. It is of no consequence for the opera tion of this type of valves whether they are mounted in continuous lines or at line ends. The desired pressure is selected by means of the set screw (4). Turning the set screw (4) clockwise will increase th e pressure, and turning it counterclockwise will reduce the pressure.

Oil temperature at the burner

Loop feeder

pipe pressure 125 °C 3,0 bar 130 °C 3,5 bar 135 °C 4,0 bar 140 °C 4,5 bar

Return

Feed

Light oil version

Heavy oil version

Page 54

Removal and Replacing the Shaft Seal of the Return Flow Nozzle Assem bly DG 75

Removal:

Before removal make a note of all relevent dimensions of the transmission lever etc.

1. Remove lock-nut (2), dom ed nut (1) and the connecting piece (3).

2. Remove end nut (4).

3. Slide out the shaft seal (must no t be re-used).

Replacement:

1. In place of the end nut (4) use location tool (5).

2. Remove plug in sleeve (6) (fitted for protection of sleeve only) and move sleeve over threads and valve needle.

3. Using a piece of pipe, slide the new seal over sleeve (6) through the locating tool (5) u ntil it bottoms in the seal housing (8). (The seal should not be compressed).

4. Remove the special tools.

5. Replace the end nut (4), connecting piece (3), lock nut (2) and domed nut (1).

6. Tighten the locking nut to the domed nut.

Page 55

Start-up

Oil Pressure Switch Air Pressure Switch

Oil pressure switch

Oil pressure switches are provid ed to burners for monitoring the oil pressure. Depending on the burner de sign, the oi l 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 depe ndi ng on the burner system data (ring line pressure, oil nozzle, 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) by pullin g it upward and reinstall it again the othe r way round. After the adjustment has been completed mak e sure to i nstall th e 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 s witching diff erence by approx. 20 % of the tot al range of the switching difference. The oil pressure switch has a facility for attaching a seal.

Type

Setting

range

Switching difference

Location

DSB 158 F... 0 - 25 bar 1,0...7,5 bar Return line acc. to EN 267; alterna-

tive if finer switch difference required

DSB 146 F... 0 - 10 bar 0,7... 4,0 bar Optional feed line and return line acc .

to EN 267; aggressive media

DSF 158 F... 0 - 25 bar 1,5... 8,0 bar Optional return line acc. to EN 267;

aggressive media, alternative if finer switch difference required

DSF 152 F... 0 - 16 bar 1,2...3,5 bar Return line acc. to EN 267; alterna-

tive if finer switch difference required

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 over an electric circuit in the case o f chang es of the actual pressure levels from the setpoint setting. The pressure switch DL 50A can be used as overpressure, vacuum or differen tia l pre ssure 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.

• Mea sure pressure on test connection (2).

• Measure vacuum on test connection (3).

• Add the measured pressures.

• Set the scale to 90% of the calcul ated value.

Certification

The pressure switch has bee n 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 differential pressure to drop below the required level. If it is necessary to test the pressure switch functions under full-load conditions this may be done by pressing button (1).

Page 56

Setting Pressure Switches and Control System

Setting of the oil pressure switch

The oil pressu re switch is factory-set. The supply pressure switch is set in such a way, that perfect atomization is guaranteed. The return p r es su re s witc h is factory-set to 2 bar. The pre-set return pressure should normally be 1 bar above the loop feeder system. After having set the correct pressure ensure that the setting screw is securely locked.

Setting of the gas pressure switch

Remove the protective hood. Measure the gas flow pressure at full load and reduce by 20 % to obtain the shutdown pressure. Proceed with turning t he scale disk until the desired shutdown pressure is opposite to the arrow. Note that scale values are approximate values only. Then slowly close the gas stop valve until the desired shut down pressur e has been reached. Readjust the scale disk until the burner stops. Put the protective hood back in place again and tighten bolts.

Setting of the air pressure switch

The differential pressure between burner housing (overpressure) and air box (subatmospheric pr essure) is me asured with the burner in full-load condition. The pressure setting of the air pressure switch must therefore be smaller than the different ial pressure measured. For adjustment, remove the pro tective ho od and turn the setting scale accordin gly.

Switching functions of air pressure switch/gas pressure switch

With increasing pressu re:

P1 opens P2 closes

With decreasing pressure:

P1 closes P2 opens

An industrial controller type KS 92 is used for the steplessly adj ustab l e bur - ners. This co ntroller has been specifically designed for use w ith bu rner systems. It is mainly employed for temperature or pressure control operations in conjunction with burner s wi t h a st eadily adjustable fuel throughput rate. A specific software system is provided for adjusting the controller to the contro lled variable, the desired setpoint range and the way of actual-value recording.

Technical documentation KS 92 PMA

Infinitely variable control (modulating) with RWF 32 controller

A universal controller type RWF 32 can also be used with infinitely variable controllable burners. This controller is specially designed for furnace temperature and pressure control of burners using constantly changing types of fuel. Depending on the use, the RWF 32 will function as either PID, PD or P controller. As the P part, which is correcting time and the D part can be adjusted to cover a wide range of limits, it is possible to adapt the control behaviou r of the installation to ex act st a ndards. The operating time of the drive for compound control of fuel and ai r mu st be at least 2 secs. for the "small fla me - nomi nal load setting" range. The actual value reading (temperature, pressure or combustion chamber pressure) is achieved by means of sensors and range or zone plugs in th e form of a resistance value. The control output of the controller is a floating three-point switch used to control reversible servomotors. The control signals for the actuating direction OPEN (y1) and CLOSED (y2) are displayed by LEDs, whilst the adaptation of the controller to the control led variab le and the requ ired specified value ra nge is effected vi a th e so-called range or zone plugs, which form the sensor part of the controller measuring bridge. The range or zone plug is also fitted with the setpoi nt scale. On the other hand, the setpoint value generator itself, which can be changed to be a remote setpo int value g enerator, is a fixed component of the controller.

Setting the controller

Setting a complete, infinitely variable heating installation required excellent technical and controll er knowledg e. The actual setting and commi ssioning of the installation is made considerably easier by the special setting instructions issued with the RWF 32 controller. Comprehensive special issues are available if required. The differential pressure between the burner housi ng (excess pressure) and the air receiver (negative pressure) is measured during the full load adjustment. The pressure set at the air pressure switch must be below the measured differ ential pre ssure. To carry out the setting remove the protective cover and turn the setting scale as required.

Gas pressure switch

Air pressure / gas pressure switch circuit

KS 92

Oil pressure switch

Page 57

Automatic Furnace Controller LFL 1... / LGK 16...

The LGK 16… type controller is designed to control and monitor burners working according to a stepwise or modulating principle. A detailed functional description with technical data and project planning information with respect to the automatic combustio n controllers can be found in the annex and in the documents

LFL 1...-7451 D LGK 16...-7785 D

Functional diagram LFL 1... / LGK 16...

A = Starting type interval A-B= Flame development interval B = Burner has reached operating

position

B-C=Burner operation

(heat generation) C-D= regular shut-off t1 Pre-ventilating time t2 Safety time t3 Pre-ignition time t4 Fuel valve enable t5 Load regulator enable t11 „OPEN“ run time of air damper t12 „CLOSE“ run time of air damper

R = Temperature or pressure

controller G = Fan motor Z = Ignition transformer BV= Fuel valve(s)

LR= Load regulator LK= Air damper RV= Steadily adjustable fuel valve FS= Signal of flame ZBV= Ignition burner valve

Page 58

Flame Monitor Sensor Current Measurement

Flame monitor with UV sensor

The UV radiation of hot flame gases is utilized for generating the flame signal. The radiation detector used is a UVsensitive tube with two electrodes and being live all the time. This UV tube will ignite when subject to light from the 190-270 nm range of the spectrum and thus cause a current t o flow to the f lame signal amplifier. The UV tube will not respond to the after-glowing refractory lining of the furnace, sunlight, daylight or light of the boiler room lighting system. The service life of the UV tube is about 10,000 hours at ambient temperatures up to 50°C; higher ambient temperatures will considerably reduce its service life.

Burners operated continuously or intermittently for more tha n 24 ho urs witho ut interruption (e.g. boiler sequence control) or burners operated on steam boilers must be equipped with the automatic furnace controller of type LGK 16... and its associated self-controlling flame monitoring circuit (QRA

5...). For data and desig n instruc tions refe r to automatic furnace controller:

LFL 1... No. 7451 D LGK 16... No. 7785 D

Sensor currents

* See technical data for automatic furnace controller LFL 1 / LGK 16...

** See data on unit KF 8832 for sensor current measu rement.

UV current measurement with QRA 5

For an accurate UV current measurement it is reco mm end ed to make use of the tester KF 8832. If a normal meter (microammeter) is used for UV current measurement it is advisable to make the measurement as shown in the figure. For this, a capacitor C = 470 μF, 1 5V (or with higher electric strength) must be integrated in the measuring c ircuit. Meter: 100 μA/Ri = 3 kΩ Connect the meter between the automatic furnace controller and the UV flame sensor QRA 5... (terminal 22 (-) and 5 (+)).

Take care to observe the right polarity.

Alignment of the UV sensor QRA 5...

The mounting flange is movable supported on the sensor tube to allow the exact alignment of the sensor window relative to the direction of incidence of the UV radiation.

NOTE: The terminal (22) must be connected to earth all the time.

Cleaning the sensor

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

Automatic controller

Minimum required

Maximum

possible Monitor with UV with UV * LFL 1... 70 μA 630 μA * LGK 16... ** **

Recommended instrumen t range: UV monitor 0 - 1000 μA

Autom. furnace controller LFL 1...

UV sensor with QRA 2...

Autom. furnace controller LGK 16...

UV Sensor with QRA 5...

Page 59

Actuator Type ARIS, 4, 4a, 5

Description

The actuator type ARIS-N is designed as a controlling element for oil/gas or dual-fuel burners wi th s li ding or modulating control concept. The actuator is equipped with a short-circuit-proof synchronous a.c. motor which drives a shaft via a maintenance free spur-ge ar unit with permanent grease lubrication. The shaft end carries a coupling for operating the controlling element for fuel and combustion air. The actuator is designed for two-wire co ntro l by c ont rollers or switching uni ts with change-over contact (single-wire control is possible). A feedback potentiometer is used as a optional feature.

Technical Data:

Voltage: 230 V +/- 10% Protection class: IP 54, DIN 400 50 Frequency: 50 Hz (60 Hz) Installation position: no restriction Operating time: 25 - 30 sec. at 90° Torque: N 4 40 Nm

N 4A 60 Nm N 5 110 Nm

Weight: N 4 3,4 kg

N 4a 3,4 kg N 5 5,8 kg

Contacts: max. 250 V 10(3)

A Ambient temperature: -15 °C till + 60 °C

Adjustment

A service switch for manual/automatic operation is provided for adjusting the actuator/controlling elemen t.

This service switch comprises:

1x manual/automatic tumbler switch 1x left/right pushbutton switch con-

nected according to the sketch (left)

For using the actuators with service switch (no handwheel) care should be taken to observe the following:

• An additional permanent phase must be installed from the actuator to the control cabinet via the terminal box or directly to the control cabinet.

• An additional terminal must be mounted in the terminal box.

Page 60

Solenoid Safety Valves

For fuel oil EL, L, M, S according to DIN 51603

TECHNICAL DATA

Function 2/2 electromagnetic safety shut-off valve and rapid action device actuated in oil-firing

equipment according to DIN 32725 (DIN EN 264). TÜV tested. Used as well in connection with atomizing oil burners according to DIN 4787 and oil firing systems with steam boilers according to TRD 411.

Port sizes G1/2 / flange Mounting Direct pipe mounting or with two threaded holes at the lower connection area (please

refer to dimensional drawing).

Mounting position Unrestricted Material specifications Valve body from brass. Internal parts from stainless steel. Bearing plate from ruby and

elastomere from oil resistant viton (FKN).

Pressure range Please refer to the table. Switching times With fuel oil EL and alternating current coils:

321 H types: switch-on operation approx. 300 ms, switch-off operation approx. 50 ms 121 G types: switch-on operation approx.50 ms, switch-off operation approx. 20 ms

Media Fuel oil EL, L, M, S (DIN 51603), please refer to the table. Filter Filters according to DIN 32727 must be connected in series to the 321 H/F valve Authorized minimum

temperature

0 - + 160°C

Ambient temperature 0 °C to 60 °C Flow factors kv = 2 to 60 (please refer to the table). The tolerance conc ern ing flo w f act ors is +/- 15 % . Electrica l components 121 G and 321 H types:

High temperature and high capacity coil with screw terminal connection.

Coil housing Metallic housing covered with epoxy resin, 360° rotating, with Pg11 cable screwing.

System of protection IP 44. Galvanized metallic housing, 360° rotating, with Pg11 cable screwing. System of protection IP 67.

Voltage ( alternating current only )

115 V / 50 HZ - 120 V / 60 Hz (T1)

V oltage tolerances + 10 % to - 10% of the line voltage. Insulation class H 180 °C for 483824 and 483541coils . Switch-on time 100 % admissible. Power rating 19 Watt

Page 61

Solenoid safety valves

321 H types Application: safety shut-off valve as

rapid acti on device. Used as well in connection with atomiz ing oi l burners according to DIN 4787 and oil firing systems with steam boilers ac cording to TRD 411. A strainer must be connected.

Type:

2/2 pre-controlled, closed when deenergized.

121 G types Application: safety shut-off valve as

rapid action device for use in return pipes of atomizing oil burners according to DIN 4787 and TRD 411. With regard to current standards this valve must be connected in series with the valve mounted in the supply line (please refer to the schematic drawing).

Type:

2/2 directly controlled, closed when deenergized by spring force. When the solenoid valve is de-energized the retur n line medium pressure (against arrow direction) s till opens the valve seat until 0,15 bar.

arrow stamped on the valve body

Page 62

2/2 Way Valve Type MK 15

General specifications Options

Ports MK threads G3/8"-G1" special threads Function NC NO Pressure range bar 0-16 / 0-40 / 0-64 / 0-100 >100 bar upon request Flow rate

4,8

Media gaseous-liquid- highly viscous-gelatinous-contaminated Flow direction A>B as marked bi-directional (max. 16 bar) Switching cycles 1/min 200 Media temperature C° DC: -40 to +100/TÜV+140

AC: -40 to +100/TÜV+140

-40 to +180

Ambient temperature C° DC: -40 to +80

AC: -40 to +80

Nominal voltage U

DC: 24 V AC: 230 V 40-60 Hz TÜV-version TÜV-version

special voltages upon request DC: 24 V

DC: 200 V

Actuation DC

direct-current magnet direct-current magnet with integrated rectifier

above 100°C and in TÜV version with seperate rectifier

Protection IP 65 Energized duty rating ED 100% Connection Pg9

Pg11

appliance plug socket acc. DIN 43 650 Form A, 4 positions x 90° terminal box

Additional equipment illuminated plug with varistor Current consumption N-coil

H-coil

24V -DC 1,60 A 230V 40-60Hz -AC 0,15 A

24V -DC 2,30 A 230V 40-60Hz -AC 0,24 A

Function

valve normally closed symbol:

valve normally open symbol:

2/2

way valve:direct acting

Orifice: DN 15 mm Design: pressure balanced,

with spring return Body materials: 1. brass (Ms 58)

2. steel, galvanized

3. brass, nickel plated

4. steel, nickel plated

5. without non-ferr . me t.

6. V4A (1.4571)

7. TÜV Valve seat: synth.resin on metal seal materials:teflon, viton,

neoprene, EPDM

Page 63

2/2 Way valve type MK 15

items circled are included in spare part kit

1 connecting port 2 connecting port 3 valve seat u nit 4 magnet unit 5 armature-control tube 6 gland 7 gland 8 retaining ring 9 locking ring

10 return spring 11 spring housing 12 locking Ring 13 hex head bolt 14 hex nut 15 lock washer 16 seal (dynamic) 17 seal (dynamic) 18 O-ring

19 gasket 20 terminal box unit 21 sealing ring 22 shading ring 23 appliance plug socket unit 24 seal

Page 64

2/2 Way Valve Type MK 20

General specifications Options

Ports MK thre ads G3/4"-G11/4" special threads Function NC NO Pressure range bar 0-16 / 0-40 / 0-64 / 0-100 >100 bar upon request Flow rate

7,4

Media gaseous-liquid- highly viscous-gelatinous-contaminated Flow direction A>B as marked bi-directional (max. 16 bar) Switching cycles 1/min 150 Media temperature C° DC: -40 to +100/TÜV+140

AC: -40 to +100/TÜV+140

-40 to +180

Ambient temperature C° DC: -40 to +80

AC: -40 to +80

Nominal voltage U

DC: 24 V AC: 230 V 40-60 Hz TÜV-version TÜV-version

special voltages upon request DC: 24 V

DC: 200 V

Actuation DC

direct-current magnet direct-current magnet with integrated rectifier

above 100°C and in TÜV version with seperate rectifier

Protection IP 65 Energized duty rating ED 100% Connection Pg9

Pg11

appliance plug socket acc. DIN 43 650 Form A, 4 positions x 90° terminal box

Additional equipment illuminated plug with varistor Current consumption N-coil

H-coil

24V -DC 1,60 A 230V 40-60Hz -AC 0,15 A

24V -DC 2,30 A 230V 40-60Hz -AC 0,24 A

Function

valve normally closed symbol:

valve normally open symbol:

2/2

way valve:direct acting

Orifice: DN 20 mm Design: pressure balanced,

with spring return Body materials: 1. brass (Ms 58)

2. steel, galvanized

3. brass, nickel plated

4. steel, nickel plated

5. without non-ferr . me t.

6. V4A (1.4571)

7. TÜV Valve seat: synth.resin on metal seal materials:teflon, viton,

neoprene, EPDM

Page 65

2/2 Way valve type MK 20

General operating instructions

To ensure the proper operation of our maintenance-free units care should be taken to observe the following points:

1. Prior to installing the valve in the pipeline system make a check that the latter system is absolute ly clean to avoid that any particles left behind by the line mounting work can be flus hed in to the valv e when taking the system into operation.

2. Valves with threaded connections should be installed to the pipeline system in a way that the frictional connection is not made in the longitudinal axis of the valve. For screwing in the pipe, t he mounting tool should be attached to the valve socket to which the pipe is mounted. For valves with flanged connection, care should be taken that no tensile, compressive and shearing loads are brought to bear on the valve because this could lead to functional trouble. The direction of flow indicated on the 2/2-way valves by arrows should in any case be adhered to.

3. For the electrical connection, unscrew the terminal box cover or install the plug connectors. Prior to connecting the cables check that the voltage applied is as stated on the rating plate. Take care to observe the marking attached to the terminal because if the connections are wrong ly fitt ed this may cause damage to the valve when taken into operation.

items circled are included in spare part kit

1 connecting port 2 connecting port 3 valve seat unit 4 magnet unit 5 armature-control tube 6 gland 7 gland 8 retaining ring 9 locking ring

10 return spring 11 spring housing 12 locking Ring 13 hex head bolt 14 hex nut 15 lock washer 16 seal (dynamic) 17 seal (dynamic) 18 O-ring

19 gasket 20 terminal box unit 21 sealing ring 22 shading ring 23 appliance plug socket unit 24 seal

Page 66

Pipe spring - Glycerine - Manometer Bimetal - Pointer - Temperature controller

Pipe spring - Glycerine - Manometer RF 63 - D 701

Port size G 1/4 A radial Housing from refined steel 1.4301 Diameter 63 mm Class 1.6

Scale range Order no.

0 - 6 bar 0 - 10 bar 0 - 16 bar 0 - 25 bar 3333 261 128 0 - 40 bar 109 016 0374 0 - 60 bar 109 811 4290 0 - 100 bar 109 811 4303

Bimetal - Pointer - Temperature controller TBW 31 H

Measuring instrument: Bi-metallic spiral Port size G 1/4 " Sleeve and locking screw on the back side Housing CrNi , Shaft length 50 mm Diameter 63 mm Class 1.0 Scale range 0 - 160 °C Order no. 109 015 9651

Page 67

Flushing and Oil Feed Start Thermostat ATH 22

(only for heavy oil)

Operation

The surface-type dual-therm ostat works according to the principle of volumetric expansion. If the temperature of the fluid in the sensor system consisting of sensor, capillary line and membrane changes this will also cause the volum e to change. The resultant lifting movement of the membrane will actuate the quick-break switch via a lever.

Switching function TR/TW/STW(STB)

If the temperature available at the temperature sensor exceeds the limit setting this will cause the switching ram of the microswitch to be relieved of load via the sensor system and the electric circuit opened or closed. In case the temperature falls below the limit setting (by the switching difference) the microswitch will be returned to its initial position.

T emperature sensor with and without protective sleeve

The temperature will be sensed by means of the temperature sensor. Make sure the temperature sensor is immersed in the fluid over its full length because otherwise the switching point may be subject to larger variations.

1 Remote line 2 Temperature sensor 3 Protective sleeve 4 Pressure spring

For code „f“ and connection mode „Ü“ the temperature sensor will be locked by fitting a clamp to the capillary line and securing the same by a screw in the extended sleev e opening. For code s „f“ and connection modes B, C, D, E, ES, Q and V the sens or is lo cked by th e manufacturer by means of the terminal attached to the capillary line.

Electrical connection

1. Opening the housing

Remove the two sealable fillister-head screws (1) at the housing top (2) and remove the latter.

1 Sealable s crews 2 Housing top 3 Housing bottom 4 H ous in g j ourn al

2. Connection

Feed the line through the self-sealing grommet Pg 11 and connect as shown on the connection diagram. The connection diagrams relating to the thermostats are fixed to the inside of their housing tops.

5 Terminal screw 6 Restart button (must move freely) 7 For type attachments s, g and b 8 For type attachment r 9 Self-sealing grommet Pg 11

Connection diagram

Codes 11, 12, 22, 120, 220, 2020 System I and II with change-over contact.

Technical data Setpoint adjustment:

For code 1: Adjust switching point fr om out s ide b y turning the setpoint screw accordingly.

For codes 2, 20, 7, 70: Remove the top of the housing and adjust the switching point by turning the setpoint screw with a s cre w dri ver watching the interior scale.

Adjusting range: 20-150°C

Maximum switching current:

AC 250 V, 10(2) A, cosϕ=1(0.6) DC 250 V, 0.25 A

Switching difference in measuring system filled with liquid

TR, TW 3+1% standard feature

6+2% on request

1.5 ± 0.5% against extra price

Permissible ambient temperature on switching head and remote line

in use filled with liquid or gas max. +80°C

Operating fluid

water, oil, air, superheated steam

Protection classification

EN 60 529-IP54

Page 68

Gas Connection

For the installation and taking into operation of the gas lines care should be taken to observe the regulations of DVGW (German Assoc iation of the Gas and Water Sector) espec ial ly DVGWTRGI (Technical Regulation for Gas Installations) and TRF (Technical Regulation for Furnaces). DIN 4756 and TRD 412 contain specifications for the construction, design and safety requirements of gas furnaces in heating installations. Furnace systems of higher operating pressures are subject to the DVGW Worksheets G 460 and G 461. The gas lines must meet specifications set out in DVGW-TR GI i n the case of furnace systems with operating pressures up to 100 m bar or above 100 mbar .

Gas control group with two gas valves and leak tester:

The gas section is designed in accordance with EN 676 and TRD 412, two gas valves and leakage tester are prescribed for burners with a capacity above 1200 kW. The operation, mounting and adjus tment of the valve leak testers is described in detail on a separate sheet .

Gas connection pressure:

The gas line must be dimensioned in accordance with the throughput rate and the available gas pressure and installed to the burner on the shortest possible way with minimum pressure loss. To provide the most effective conditions for start-up, take care that the burner and gas stop valv e are i nstal led with th e minimum possible distance between

one another. This means that the 2

gas valve (looking in the direction of the gas flow) sho uld be mounted in the immediate vicinity of the burner. Note the gas pressure loss of the gas control group and burner. The gas control group can be connected directly to the gas feed line. Note the order in which the valves and instruments are mounted and the direction of flow. Prior to installation and taking into operation, check the valves and instruments and the connection fittings for the possible accumulation of dirt and foreign matter.

1 Gas stop valve 2 Ignition gas pressure regulator 3 Ignition gas solenoid valves 4 Gas filter 5 Pressure gauge with pushbutton

valve 6 Test burner 7 Gas meter 8 Gas pressure switch 10 Gas pressure regulator with safety

blow-off valve 11 Safety blow-off valve 12 Gas motor valve 1/solenoid valve 13 Gas motor valve 2/solenoid valve 14 Compensator 15 Gas butterfly control valve 16 Gas pilot burner 17 Burner

Gas connection > 100 mbar

Ignition gas connection min. 50 mbar max. 150 mbar

Page 69

Gas Motor Valve VK

Gas motor valve VK..

- Automatic shut-off valve of Class A according to EN 161.

- Sturdy des ig n for long serv ic e life .

- Energy-saving through motor selfstop.

- Available in single-stag e or double stage design with signal switch.

- Valve housing available in GGG 50.

- Valve top can be supplied in explosion-proof design.

- EC prototype tested and certified

(CE).

Application

The gas motor valve is used to ensure and control the gas and air supply to gas burners and other gas-firing equipment, also for two-stage operation. The VK..G with GGG 50 housing meets the requirements according to TRD 412, par. 4.2 (application in outdoor installations), par. 5.1 (shut-o ff valve outside of the boiler room) and GUV 17.4 (use in landfills). In areas subject to an explosion hazard (zones 1 and 2) it is recommended to use VK..X, e.g. in lacquer and varnish factories, paint shops, refineries, chemical plants, sewage treatment plants, landfills, gas/oil extraction plants, etc.

Operation

The motor valve type VK is a hydraulically actuated safety valve which is in closed posit ion when dead. On application of mains voltage the internal pump of the valve will build up an oil pressure which causes the val v e disk to be forced down slowly via a piston. The pump will stop as soon as the fully opened position has been reached. As the pressure decreases the pump will be sh ortly run again. For clo sing the valve, shut off the voltage which will cause the oil pressure to return to zero and the closing spring force down the valve disk within 1 s.

General technical data

Type of gas: City gas, natural gas, liquid gas (gas eous state) and air; also suitable for biogas and landfill gas

Valve housing: AlSi for VK..A DN 40 to DN 200; GGG 50 for VK..G DN 50 to DN 200; inside and outside with epo xy resin powder coating. The two housings can be combined with different tops.

Maximum inlet pressure: see Table of

Data; VK..G are pressure proof up to 8 bar and pressure surge proof

up to 20 bar. Valve top: AlSi Valve disk sealing:

Perbunan up to DN 150 Polyurethane for DN 200 alternatively, Viton for DN 40-150 acc. to EN 161, Class A, Group 2 Measuring or pilot flame connection Rp on either side of input and in output; with stainless steel screen to protect valve seat and valve sealing.

Inside thread Rp according to ISO 7-1 Flange PN 16 according to ISO 7005 Closing time: 0.8 s

Ambient temperature: see versions Storage and handling temperature:

-40°C to +60°C Mains voltage: see versions Power consumption: see table Duty factor: CD 100% Connection: conduit thread Pg 13.5 Protection classification: 1 Degree of enclosure: IP 54 according

to IEC 529 Take care to observe the regulations

of the local electric power supply companies.

Op e n i ng t i me : VK VK . . H DN 40 5 s DN 50 - 65 8 s 12 s DN 80 -100 10 s 18 s DN 125 - 200 13 s 24 s

Page 70

Gas Motor Valve VK

VK.., VK..H VK..: single-stage top; slowly

opening VK..H: top with higher actuating force

for higher input pressures; slowly opening

VK.., VK..H:

For electrical connection see figure at the top left.

The following versions are available:

- with volumetric flow control valve (standard);

- with signal switch (option);

- with holding relay for manual restart (option);

- with standard appliance plug according to DIN 43650 (option)

VK..Z

Top of double-stage type; slowly opening. For electrical conne ction see figure centre left. The following versions are available:

- with volumetric flow control valve (standard): The 1st stage can be adjusted with a switch between 0% and 90% of the maximum output. The 2nd stage can be adjusted with the volumetric flow control valve from the botto m between 0% and 100%. Factory setting: maximum volumetric flow rate.

- with signal switch (standard)

VK... VK..H, VK..Z Technical data

Mains voltage: 220/240 V~ +10/-15% 50 Hz

(standard) 220 V~ +10/-15% 60 Hz 200 V~ +10/-10% 50/60 Hz 120 V~ +10/-15% 60 Hz 110 V~ +10/-15% 50/60 Hz 100 V~ +10/- 5% 50/60 Hz

Ambient temperature: -15°C to +60°C Installation:

in horizontal or vertical lines

Page 71

Gas Pressure Regulator

Gas pressure regulator with separate safety blow-off valve

Blow-off line R 1"

Safety blow-off valve

Instrument line ∅ 12 mm

appr. 10 x d

Gas pressure regulator with built-in safety blow-off valve

Vent line 1/2"

Instrument line

appr. 10 x d

Blow-off line

Safety blow-off

12 mm outside ∅

valve

Page 72

Gas Pressure Regulator with Safety Diaphragm, Inlet Pressure Compensator, Zero Lock

Installation and Adjustment

Setpoint adjustment

The setpoint will be adjusted by selecting the desired range of the setpoint spring and adjusting the setting spring accordingly. The layout of ranges is according to the spring configuration.

Instrument line

It will not be necessary to reposition the instrument line bec ause the con troller is equipped with an internal pulse sensor as a standard f eature.

Inlet pressure variations

Any variations between the minimum and maximum inlet pressure levels will be compensated for by the compens ator diaphragm to avoid outlet pressure variations.

Installation

Prior to installation check that the connecting lines and regulators are free of dirt. Dirt-carrying gas may cause damage to the seat and cone of the regulator. For the installation take care to observe the direction of the arrow. Hold regulators with threade d connec tions only by means of suitable tools engaging the surfaces intended for this purpose. For the connection of flanged joints take care to tighten the bolts by even amounts all around.

Control and start-up

With the setpoint setting known to be in its correct posi tion : Proceed with slowly opening the sto p valve upstream of the regulator. Then turn on the gas-consuming equipment. Depending on the mounting position it might be necessary to slightly readjust the pressure (turning the setpoint setting screw clockwise or counterclockwise will increase or decrease the pressure, respectively). With the setpoint s etting no t known o r in its incorrect positi on: Proceed with fully relieving the setpoint spring of load (turning counterclockwise); open the stop valve slow ly and cautiously; set the desired setpoint to an approxim ate position with the gasconsuming equipment not turned on and proceed with the exact setpoint setting at nominal load. If the setting rang e of the setpoint spring is not sufficient, select the correct spring from the table of springs.

Maintenance

The gas pressure regulator is maintenance free. Dirt-carrying gas ma y how ever necessitate an occasional cleaning of the unit. In case of a failure of the working, safety or compensati ng dia phragms due to the impact of excessively high pressure it will be necessary to order a new measuring element for the particular ty pe (all functiona l part s of the regulator available as a kit).

1 Housing bottom 2 Regulator seat 3 Regulator sealing 4 Regulator disk 5 Bottom spacer sleeve 6 Compensating diaphragm 7 Top spacer sleeve 8 Override tube 9 Working diaphragm 10 Safety diaphragm 11 Diaphragm disk 12 Sett ing pressure spring 13 Screw 14 Screw plug

15 Adjusting screw 16 Screw cap 17 Position indicator for

DN 40/DN 150 18 Cover 19 Bottom cover 20 R1/4" thread on either side of

inlet pressure chamber for

inserting the test socket 21 Leakage gas connection

R 1/4" for DN15/DN25 (R 1/2"/R

1") R1/2" for DN 40/DN150 22 Diaphragm cup 23 Diaphragm plate

Page 73

Gas Pressure Regulator with Integrated Safety Valve

Installation and Adjustment

The gas pressure regulator has been designed to ensure a constant outlet pressure with fluctuating inlet pressure and varying consumption rates. It is especially used for applications requiring very short response times, e.g. in the feed line to burner systems, industrial furnaces, etc. The gas pressure regulator is installed by the exclusive use of spring-loaded mountings so that it can be arranged in any desired position. A common housing accommodates the gas pressure regulator and a safety shut-off valve which is set to stop the gas supply in case of overpressure and/or lack of pressure.

Installation

The gas pressure regulator must be installed with the arrow pointing in the direction of the gas flow . T wo instrumen t lines must be fitted, one to the bottom diaphragm cup of the reg ulator p art a nd one to the upper diaphrag m cover of the safety shut-off valve (approx. 10 D downstream of the control unit). These lines should be of steel type with an outside diameter of 12 mm. The Ermeto self-sealing couplings are provided by the manufacturer.

T aking into opera tion

Open the gas shut -off valv e very s lowly. Watch the outlet pressure on the pressure gauge and readjust the load spring if required. Take care for adjustment that the gas is not flowing because otherwise the closing pressure will be added to the measured result.

Operation

The gas will flow through the regulator housing in the direction of the arrow. The main diaphragm will be charged with pressure to th e outl et side from the bottom via an instrument line. The load spring is preset to the desired outlet pressure. The single-seat valve is directly hung and isolated from the inlet pressure by an in termediate diaphragm. The diaphragm of the safety shut-off valve is charged with outlet pressure via an instrument line. Ove rpressure and/or lack of pressure will cause the measuring element to lift or lower. This will actuate the tripping m echanis m with the closing spring pressing the valve disk against the valve seat.

1 Setting screw 2 Load spring 3 Main diaphragm 4 Vent openi ng R 3/8" 5 Instrument connection R 3/8" 6 Inlet pressure compensating

diaphragm 7 Valve seat 8 Valve sealing 9 Closing cover 10 Instrument connection R 1/4"

1 1 Vent opening 12 Inlet pressure compensat ing val

13 Safety shut-off valve seat 14 Valve sealing 15 Closing spring 16 Safety shut-off valve diaphragm 17 Maximum spring 18 Setting screw 19 Pull knob

Page 74

Gas Filter Safety Vent Valve

Installation and mounting of the gas filter

The gas filter may be installed in any desired position. Take care only to observe the direction of flow of the gas (arrow on filter housing). Make sure there is adequate clearance to facilitate the removal of the cover and replacement of the filter cartridge.

Filter replacement

The filter cartridge should be replaced by a new one as soon as a high pressure drop is noticed. If a new filter cartridge is not at hand it will be possible to wash the filter mat in 40°C water a dding some light-duty detergent. Allo w the mat to dry before reinstallation.

NOTE: For the installation of the filter mat take care to observ e the marki ng or sticker.

Safety vent valve

Connection: R 1“, R 11/2“ Relief pressure: max. 1 bar Single-seat valve Tight zero lock Maintenance free

The safety vent valve type SL 10 is provided to relieve short-time pressure surges upstream of burner installations or to avoid pressure increases beyond an acceptable limit.

1 Setting screw 2 Load spring 3 Diaphragm 4 Vent opening R „ 5 Internal influencing featu re 6 Valve sealing 7 Valve seat 8 Closing cover

Page 75

Diagram Pressure Loss

Pressure loss with fully opened gas dampers

For the various gas qualities it will be necessary to multiply the p value read as a function of the volumetric flow rate by the specific gravity of the gas. Reading example: damper dia. = 50 mm; V = 150 m³/h natural gas; Δp reading = 6 mbar; specific gravity of natural gas = 0.81 kg/m³; results in a pressure loss with fully opened gas damper, Δp = 0.81 x 6 = 4.86 mbar

Gas volumetric flow rate [m³/h]

Pressure loss Δp [mbar]

Page 76

Discharge Speed, Gas Nozzles

100

110

120

012345678910

[MW]

W [m/s]

(

RPD 30 u. 40 8 nozzles

100

110

120

130

140

150

0 2 4 6 8 10 12 14 16 18 20 22

[MW]

W [m/s]

35,6

RPD 50, 60 u. 70 12 nozzles

Page 77

Discharge Speed, Gas Nozzles

100

0 5 10 15 20 25 30 35 40

[MW]

W [m/s]

35,6

RPD 80 16 nozzles

100

0 5 10 15 20 25 30 35 40 45 50

[MW]

W [m/s]

35,6

RPD 90 18 nozzles

Page 78

Preoperational Checks Functional Flow Gas Start-up

Preoperational checks

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

• Take care to observe t he operating instructions supplied by the boiler manufacturer.

• Check the complete system for correct wiring of all o f i ts items incl us iv e of the valves and instruments.

• Check the air fan motor for correct direction of rotation.

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

• Check for adequate fuel supply, sufficient gas connection pressure, and sufficient oil contained in tank.

• Make a leak test of the fuel-carrying lines (ensure no air is contained).

• Check that the exhaust gas ports are opened and fresh ai r is su pplied at the required rate.

• Make sure the burner is in starting position.

• Check that automatic furnace controller is unlocked.

A leak test should be made with the complete gas valves and instruments group using the 1.1-fold operating pressure but minimum 60 mbar above the operating pressure level. Joints like flanges, screwed unions, etc. must be sprayed with foaming agents and chekked for absence of leaks. Take care to observe the maximum operating pressure of the valves and instruments. After the temperature ha s been all owed to equalize make s ure th e test pressure does not drop for the subsequent test period of 10 mi nutes.

Gas line venting: The gas line and valves/instruments must be vented before t aking the burne r into operation. If an inflammable gas mixture is detected make sure to discharge it into the open atmosphere through a vent line and make a check with a test burner in the outlet area of the burner.

Functional test without fuel

Check the burner for proper functional order without using a fuel. In gas operating mode make sure to close the gas stop valve. In oil operating mode the test is made with closed stop valve in the feed line to the burner.

Start-up

For taking the duoblock burner type RPD into operatio n, it wi ll be require d to carefully adjust the burner system by duly following the adjusting instructions and procedures. After the burner and boiler have been tested in the way described above, the burner may be taken into operation.

Gas start-up

• Set the emergency and main sw itch es to their „ON“ positions.

• Open the ball stop valve upstream of the gas valve and check the gas pressure on the pressure gauge mounted upstream of the gas pressure controller.

• Set the fuel selector switch to its „Gas“ position.

• Set the control switch to its position „1“.

• Set the output selector switch to its position „0“ = Partial Load or „1“ = Regulating Load, as required. For adjusting the burner make sure the switch is in its „Regulating Load“ position.

• Set the service switch also to its position „1“.

• The „Manual-Automatic“ selector switch is in its „Automatic“ position during start-up and operation.

• When adjusting the burner be sure the switch is changed over to its „Manual“ position.

• Unlock the automatic furnace controller. If a leak test is made with the valves the automatic furnace controller should not be unlocked until the leak test has been successfully comple ted. The burner will start according to the program flow preset by the automatic furnace controller. The burner will now be in operation. In case a leak is detected with the valves the program will not proceed to the automatic furnace controller.

Page 79

Start-up Light Oil

Checking Procedure

Function of the steplessly controlling light oil burner

The light oil is supplied to the high-pressure pump by an oil pump via ring line, gas-air separator and service tan k. The light oil is flushed via the pressure control valve on the oil control block. When closing this flushing valve the oil pressure will build up and open the hydraulic ball-type valves in the feed and return lines. The pressure control valve (in oil con trol block) instal led downstream of the highpressure pump will keep the oil pressure at the constant level of 28- 30 bar in accordance with an overflow principle. The nozzle rod assembly has 2 conne ctions, the oil feed and the oil return connections. Two types o f nozzle rods can optionally be used, i.e. the RDG/RDN and the MAT nozzle rods. In the light oil mode it will be pos sible to actuate, the feed and return valves at the same time. After the nozzle needle valve has opened in the nozzle rod the oil pressure will be controlled via an oil controller in the return line (minimum pressure approx. 3-5 bar; maximum pres su re approx. 16-18 bar). If the compound controller is increased to maximum outp ut, the o il pres sure w ill be brought to approx. 16-18 bar (maximum output of nozzle). This output must correspond to the rated output of the heat generator as shown in the nozzle output diagram. Simultaneously with the oil flow rate control, the air flow rate control cam of the compound control system will control the air flow rate required for the combustion of the oil quantity supplied.

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 fill ed with water.

- Check the complete system for c orrect electrical wiring.

- Check the air fan and pump motor for correct direction of rotation.

- For checking the direction of rotation of the air fan and pump motors (direct connection) shortly actuate or press the contactor.

- In star-delta connection layouts it will be necessary to actuate th e mains and star contactors at the same time.

- Check the correct direction of rotation of the oil pump by comp ari son with the direction-of-rotation arrow stamped to the pump.

- Check for the proper setting of the temperature and pressure controllers, limiters, safety switches and elec tric al limit switches.

- Bleed the fuel carrying lines, pumps and pre-heaters (make sure no air is contained).

- Check that the tank, lines and oil p ump are filled with oil and that th e proper oi l nozzle has been fitted.

- Make a test of the hydraulic oil sy stem for absence of leaks.

- Check the exhaust gas ports are opened and sufficient fresh air is taken in.

- With the burner in starting position check that air damper is closed.

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

Oil start-up

- Open all stop valves of the oil supply system; fill pumps with oil.

- Install feed pressure gauges, vacuum gauges, pumps, etc.

- If a ring line is provided fill this with oil and take it into operation. Check oil temperature.

NOTE: The hydraulic sy ste m is factoryfilled with test oil which might lead to ignition trouble during initial start-up. To protect the pump the oil pressure controller is factory-set at a low pressure only. When starting the burner make sure to increase the oil pressure to operating level gradually.

Prior to initial fuel feed start make a functional test of the burner program flow.

Disconnect the lifting magnet of the nozzle needle valve (solenoid valve) by reference to the wiring diagram. Start the burner and check the program flow for correct sequence of start-up operations.

1. Flush via oil control block.

2. Fan.

3. Air damper pre-ventilation (check

limit switch se tting).

4. Check air pre ssure.

5. Air damper starting load (check

limit switch se tting).

6. Ignition (ignition gas valves).

7. Fuel valves.

8. Shutdown on trouble after safety

time has run down (se e autom atic furnace controller).

9. Unlock automatic furnace control-

ler.

Page 80

Start-up Heavy Oil

Checking Procedure

Function of the steplessly controlling heavy oil burner

The pumpable heavy oil is supplied to the high-pressure pump by an oil pump via ring line, gas-air separator and service tank. The high-pressure pump circulates the heavy oil through the preheater, pressure control valve and flushing valve of the oil control block. In this process the oil is heated up and brought to atomizing viscosity (approx. 12 to 15 cSt). The flushing valve will be closed after the preset oil temperature has been reached. The pressure control valve installed downstream of the high-pressure burner pump will keep the oil pressure at the constant level of 28-30 bar in accordance with an overflow principle. The nozzle rod assembly has 2 conne ctions, the oil feed and the oil return connections. Two types o f nozzle rods can optionally be used, i.e. the DG75 and the MAT nozzle rods. If the DG75 nozzle rod is used, the solenoid valves will be opened in the feed and return lines for approx. 45 seconds prior to fuel feed start. A flushing process is started via the nozzle rod and output controller so as to ensure the required fuel oil temperature also immediately upstream of the nozzle. A flushing operation is not used with burners having the MAT nozzle rod. In this case the required viscosity is achieved by heating the nozzle rod. After the solenoid valves or nozzle needle have opened, the oil pressure will be controlled via an oil controller in the return line (minimum pressure approx. 3-5 bar; maximum pres su re approx. 16-18 bar). If the compound controller is increased to maximum outp ut, the o il pres sure w ill be brought to approx. 16-18 bar (maximum output of nozzle). This output must correspond to the rated output of the heat generator as shown in the nozzle output diagram. Simultaneously with the oil flow rate control, the air flow rate control cam of the compound control system will control the air flow rate required for the combustion of the oil quantity supplied.

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 fill ed with water.

- Check the complete system for c orrect electrical wiring.

- Check the air fan and pump motor for correct direction of rotation.

- For checking the direction of rotation of the air fan and pump motors (direct connection) shortly actuate or press the contactor. In star-delta connection layouts it will be necessary to actuate th e mains and star contactors at the same time. Check the correct direction of rotation of the oil pump by comp ari son with the direction-of-rotation arrow stamped to the pump.

- Check for the proper setting of the temperature and pressure controllers, limiters, safety switches and elec tric al limit switches.

- Bleed the fuel carrying lines, pumps and pre-heaters (make sure no air is contained).

- Check that the tank, lines and oil p ump are filled with oil and that th e proper oi l nozzle has been fitted.

- Make a test of the hydraulic oil sy stem for absence of leaks.

- Check the exhaust gas ports are opened and sufficient fresh air is taken in.

- With the burner in starting position check that air damper is closed.

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

Oil start-up

- Open all stop valves of the oil supply system; fill pumps with oil.

- Install feed pressure gauges, vacuum gauges, pumps, etc.

- If a ring line is provided fill this with oil and take it into operation. Check oil temperature (min. 50- 60°C d epe ndi ng on viscosity).

NOTE: The hydraulic syste m is factoryfilled with test oil which might lead to ignition trouble during initial start-up. To protect the pump the oil pressure controller is factory-set at a low pressure only. When starting the burner make sure to increase the oil pressure to operating level gradually.

Prior to initial fuel feed start make a functional test of the burner program flow.

Disconnect the lifting magnet of the nozzle needle valve (solenoid valve) by reference to the wiring diagram. Start the burner and check the program flow for correct sequence of start-up operations.

1. Flushing (oil temperature).

2. Fan.

3. Air damper pre-ventilation (check

limit switch se tting).

4. Check air pre ssure.

5. Air damper starting load (check

limit switch se tting).

6. Ignition (ignition gas valves).

7. Fuel valves.

8. Shutdown on trouble after safety

time has run down (se e autom atic furnace controller).

9. Unlock automatic furnace control-

ler.

Page 81

Viscosity as a Function of Oil Temperature

Temperature [°F]

Kinematic viscosity ν [mm²/s = cSt]

Max. feeding viscosity

Temperature [°C]

max. Atomizing viscosity heavy fuel oil

usual feeding viscosity: 60 - 100 cSt usual atomizing viscosity: 10 cSt

Page 82

Oil Start-up Burner Shutdown Measures in Case of Trouble

Oil start-up

• Set the emergency and main sw itch es to „ON“.

• Open all stop valves in the oil supply system. If a ring line system is provided for oil supply the ring line pump must be started.

• Set the fuel selector switch t o the „Oil“ position.

• Set the control switch to position „1“.

• Set the output selector switch to position „0“ (= partial load) or „1“ (= regulating load). Select the „regulating load“ position for adjusting the burner.

• The „Manual/Automatic“ selector switch must be in its „Automatic“ position during the start-up phase and during operation.

• Change over to „Manual“ mode for adjusting the burner.

• Unlock the automatic furnace controller. The burner will start in accordance with the program flow of the auto matic furnace controller. The burner is in operation now.

Burner shutdown

1. Set the control switch to position „0“.

2. Set the fuel selector switch to position „0“.

3. Close the gas stop valve or oil stop valves.

4. For short periods of shutdown the fuel stop valves may remain in their open positions.

5. For longer periods of shutdown and for inspections make sure to set all switches to their „OFF“ positions and close the gas stop valve and oil stop valves.

6. Have the furnace system inspected at least once a year by the local service company to ensure its efficient operation and compliance with the applicable air pollution contr ol regulations.

7. Oil combustion should be without the development of smoke and the flame should burn steadily without the formation of soot. No visible smoke must emerge from the chimney and no smell of oil must occur.

8. Any conditions deviating from standards and any faults should immediately be reported to the installer of the system and eliminated without delay.

Fuel change-over

1. Set the fuel selector switch to it s position „0“ and allow the afterventilation period to run down.

2. Set the selector s witc h to the desired fuel type.

Measures in case of trouble

Any trouble of the burner will be indicated by the illum inated push button switc h (red light) in the control cabinet or automatic furnace controller. If the trouble can be eliminate d the autom atic furnac e controller can be unlocked by pressing any of the two illuminated pushbutton switches causing the burner to restart in accordance with the program . If the burner returns to its trouble position the local service personnel should be cal led to site. In case of a negative result of the valve leak test make sure to close the gas stop valve at once and call the service personnel to site. The burner may be run in oil mode until the trouble has been eliminated.

Regular checks and maintenance measures

• Check the gas pressure o r oil pre ssure on the pressure gauge.

• Check the safety time of the automat ic furnace controller by pulling out the UV flame monitor.

• The safety time must be 5 se conds for oil and 2 seconds for natural gas for start-up while during normal opera tio n the burner must be shut down without delay.

• Clean the flame sensors if dirt has accumulated.

• In case the burner is operated with the same fuel type for longer periods it should be shortly run with the other fuel type at an interval of 3-4 weeks.

• Clean all filters at regular intervals and check for tight condition. Clean the oil filter each time a fresh oil supply has been taken in. Rinse the filter with pure benzine or similar solvent and blow out with compres sed air . Remove residual dirt from filter housing, if any. Wash the filter mat of gas filters with water (max. 40°C) adding a commercial light-duty deterge nt if req uired. Do not hose down the filters with a highpressure water jet. Allow the filter mat to dry and reinstall in filter housing. When reinstalling the filter cartridge take care that it is located by the filter housing groove and the filter cover.

Page 83

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

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

) content as low as possible and a carbon

dioxide (CO

) 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.

Determining the volumetric gas flow rate

The thermal furnace output of a boiler (Q

) is the amount of h ea t supp lied w ith

the gas in a unit of time. When taking the burner into operation the volumetric fuel flow rate should be selected according to the nominal thermal capacity of the boiler.

Example:

Mean barometer readings

Nom. thermal output Q

1000 kW

Boiler efficiency n

0,88

Calorific value of gasH

9,1 kWh/m³

Gas pressure p

100 mbar

Barometer reading p

amb

980 mbar

Gas temperature t

gas

15 °C

Standard pressure p

1013 mbar

Sea level

[m]

Mean barometer readings

[mbar] Aachen 205 991 Berlin 50 1009 Dresden 120 1000 Erfurt 315 978 Frankfurt/M. 104 1004 Hamburg 22 1011 Cologne 45 1009 Leipzig 130 998 Magdeburg 79 1005 Munich 526 955 Nuremberg 310 980 Rostock 4 1013 Stuttgart 297 984 Schwerin 59 1010 Ulm 479 960

Volumetric gas flow rate at STP:

Volumetric gas flo w rate in operating condition:

Ratio between O2- and CO2- for natural gas H (CO

2max

=11,86%)

%CO2 %O2 %CO2

0,00 11,86 3,00 10,16 0,10 11,80 3,10 10,10 0,20 11,75 3,20 10,04 0,30 11,69 3,30 9,99 0,40 11,63 3,40 9,93 0,50 11,58 3,50 9,87 0,60 11,52 3,60 9,82 0,70 11,46 3,70 9,76 0,80 11,41 3,80 9,70 0,90 11,35 3,90 9,65 1,00 11,29 4,00 9,59 1,10 11,24 4,10 9,53 1,20 11,18 4,20 9,48 1,30 11,12 4,30 9,42 1,40 11,07 4,40 9,36 1,50 11,01 4,50 9,31 1,60 10,95 4,60 9,25 1,70 10,90 4,70 9,19 1,80 10,84 4,80 9,14 1,90 10,78 4,90 9,08 2,00 10,73 5,00 9,02 2,10 10,67 5,10 8,97 2,20 10,61 5,20 8,91 2,30 10,55 5,30 8,85 2,40 10,50 5,40 8,80 2,50 10,44 5,50 8,74 2,60 10,38 5,60 8,68 2,70 10,33 5,70 8,63 2,80 10,27 5,80 8,57 2,90 10,21 5,90 8,51

O221

2max

2gem

–

2max

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

× %==

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

max =15,40%)

% O

% 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

2max

2gem

–

2max

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

× %==

600

700

800

900

1000

0 1000 2000 3000 4000 5000

H öhe in m.ü.M.

Mittlerer Luftdruck in mbar

0960

1013,2

Altitude in m above sea level

Mean atmospheric pressure in mbar

Page 84

SO2-content in Exhaust Gas from Light Oil and Heavy Oil Combustion

SO2 -content in exhaust gas from light oil combustion

SO2 -content in exhaust gas from heavy oil combustion

SO2 in dry exhaust gas

Sulphur content in fuel [% by wt.]

[% by vol.]

Sulphur content in fuel [% by wt.]

SO2 in dry exhaust gas

[

]

1,2 % by wt.

2,8 % by wt.= max. acc.

to DIN 51 603

Page 85

O2, CO2, Lambda Conversion Table

Natural Gas

Relation between O2 and CO2 value for natural gas (CO

2max

=11,8 %)

%CO

Air index

0,00 11,80 1,00 0,10 11,74 1,00 0,20 11,69 1,01 0,30 11,63 1,01 0,40 11,58 1,02 0,50 11,52 1,02 0,60 11,46 1,03 0,70 11,41 1,03 0,80 11,35 1,04 0,90 11,29 1,04

1,00 11,24 1,05 1,10 11,18 1,06 1,20 11,13 1,06 1,30 11,07 1,07 1,40 11,01 1,07 1,50 10,96 1,08 1,60 10,90 1,08 1,70 10,84 1,09 1,80 10,79 1,09 1,90 10,73 1,10

2,00 10,68 1,11 2,10 10,62 1,11 2,20 10,56 1,12 2,30 10,51 1,12 2,40 10,45 1,13 2,50 10,40 1,14 2,60 10,34 1,14 2,70 10,28 1,15 2,80 10,23 1,15 2,90 10,17 1,16

3,00 10,11 1,17 3,10 10,06 1,17 3,20 10,00 1,18 3,30 9,95 1,19 3,40 9,89 1,19 3,50 9,83 1,20 3,60 9,78 1,21 3,70 9,72 1,21 3,80 9,66 1,22 3,90 9,61 1,23

O221

2max

2gem

–

2max

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

× %==

%CO

Air index

4,00 9,55 1,24 4,10 9,50 1,24 4,20 9,44 1,25 4,30 9,38 1,26 4,40 9,33 1,27 4,50 9,27 1,27 4,60 9,22 1,28 4,70 9,16 1,29 4,80 9,10 1,30 4,90 9,05 1,30

5,00 8,99 1,31 5,10 8,93 1,32 5,20 8,88 1,33 5,30 8,82 1,34 5,40 8,77 1,35 5,50 8,71 1,35 5,60 8,65 1,36 5,70 8,60 1,37 5,80 8,54 1,38 5,90 8,48 1,39

6,00 8,43 1,40 6,10 8,37 1,41 6,20 8,32 1,42 6,30 8,26 1,43 6,40 8,20 1,44 6,50 8,15 1,45 6,60 8,09 1,46 6,70 8,04 1,47 6,80 7,98 1,48 6,90 7,92 1,49

7,00 7,87 1,50 7,10 7,81 1,51 7,20 7,75 1,52 7,30 7,70 1,53 7,40 7,64 1,54 7,50 7,59 1,56 7,60 7,53 1,57 7,70 7,47 1,58 7,80 7,42 1,59 7,90 7,36 1,60

%CO

Air index

8,00 7,30 1,62 8,10 7,25 1,63 8,20 7,19 1,64 8,30 7,14 1,65 8,40 7,08 1,67 8,50 7,02 1,68 8,60 6,97 1,69 8,70 6,91 1,71 8,80 6,86 1,72 8,90 6,80 1,74

9,00 6,74 1,75 9,10 6,69 1,76 9,20 6,63 1,78 9,30 6,57 1,79 9,40 6,52 1,81 9,50 6,46 1,83 9,60 6,41 1,84 9,70 6,35 1,86 9,80 6,29 1,87 9,90 6,24 1,89

10,00 6,18 1,91 10,10 6,12 1,93 10,20 6,07 1,94 10,30 6,01 1,96 10,40 5,96 1,98 10,50 5,90 2,00 10,60 5,84 2,02 10,70 5,79 2,04 10,80 5,73 2,06 10,90 5,68 2,08

11,00 5,62 2,10 11,10 5,56 2,12 11,20 5,51 2,14 11,30 5,45 2,16 11,40 5,39 2,19 11,50 5,34 2,21 11,60 5,28 2,23 11,70 5,23 2,26 11,80 5,17 2,28 11,90 5,11 2,31

Page 86

O2, CO2, Lambda Conversion Table

Liquid Gas

Relation between O2 and CO2 value for for liquid gas (CO

2max

=13,8 %)

%CO

Air index

0,00 13,80 1,00 0,10 13,73 1,00 0,20 13,67 1,01 0,30 13,60 1,01 0,40 16,54 1,02 0,50 13,47 1,02 0,60 13,41 1,03 0,70 13,34 1,03 0,80 13,27 1,04 0,90 13,21 1,04

1,00 13,14 1,05 1,10 13,08 1,06 1,20 13,01 1,06 1,30 12,95 1,07 1,40 12,88 1,07 1,50 12,81 1,08 1,60 12,75 1,08 1,70 12,68 1,09 1,80 12,62 1,09 1,90 12,55 1,10

2,00 12,49 1,11 2,10 12,42 1,11 2,20 12,35 1,12 2,30 12,29 1,12 2,40 12,22 1,13 2,50 12,16 1,14 2,60 12,09 1,14 2,70 12,03 1,15 2,80 11,96 1,15 2,90 11,89 1,16

3,00 11,83 1,17 3,10 11,76 1,17 3,20 11,70 1,18 3,30 11,63 1,19 3,40 11,57 1,19 3,50 11,50 1,20 3,60 11,43 1,21 3,70 11,37 1,21 3,80 11,30 1,22 3,90 11,24 1,23

O221

2max

2gem

–

2max

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

× %==

%CO

Air index

4,00 11,17 1,24 4,10 11,11 1,24 4,20 11,04 1,25 4,30 10,97 1,26 4,40 10,91 1,27 4,50 10,84 1,27 4,60 10,78 1,28 4,70 10,71 1,29 4,80 10,65 1,30 4,90 10,58 1,30

5,00 10,51 1,31 5,10 10,45 1,32 5,20 10,38 1,33 5,30 10,32 1,34 5,40 10,25 1,35 5,50 10,19 1,35 5,60 10,12 1,36 5,70 10,05 1,37 5,80 9,99 1,38 5,90 9,92 1,39

6,00 9,86 1,40 6,10 9,79 1,41 6,20 9,73 1,42 6,30 9,66 1,43 6,40 9,59 1,44 6,50 9,53 1,45 6,60 9,46 1,46 6,70 9,40 1,47 6,80 9,33 1,48 6,90 9,27 1,49

7,00 9,20 1,50 7,10 9,13 1,51 7,20 9,07 1,52 7,30 9,00 1,53 7,40 8,94 1,54 7,50 8,87 1,56 7,60 8,81 1,57 7,70 8,74 1,58 7,80 8,67 1,59 7,90 8,61 1,60

%CO

Air index

8,00 8,54 1,62 8,10 8,48 1,63 8,20 8,41 1,64 8,30 8,35 1,65 8,40 8,28 1,67 8,50 8,21 1,68 8,60 8,15 1,69 8,70 8,08 1,71 8,80 8,02 1,72 8,90 7,95 1,74

9,00 7,89 1,75 9,10 7,82 1,76 9,20 7,75 1,78 9,30 7,69 1,79 9,40 7,62 1,81 9,50 7,56 1,83 9,60 7,49 1,84 9,70 7,43 1,86 9,80 7,36 1,87 9,90 7,29 1,89

10,00 7,23 1,91 10,10 7,16 1,93 10,20 7,10 1,94 10,30 7,03 1,96 10,40 6,97 1,98 10,50 6,90 2,00 10,60 6,83 2,02 10,70 6,77 2,04 10,80 6,70 2,06 10,90 6,64 2,08

11,00 6,57 2,10 11,10 6,51 2,12 11,20 6,44 2,14 11,30 6,37 2,16 11,40 6,31 2,19 11,50 6,24 2,21 11,60 6,18 2,23 11,70 6,11 2,26 11,80 6,05 2,28 11,90 5,98 2,31

Page 87

O2, CO2, Lambda Conversion Table

Light Fuel Oil

Relation between O2 and CO2 value for light fuel oil (CO

2max

=15,4 %)

%CO

Air index

0,00 15,40 1,00 0,10 15,33 1,00 0,20 15,25 1,01 0,30 15,18 1,01 0,40 15,11 1,02 0,50 15,03 1,02 0,60 14,96 1,03 0,70 14,89 1,03 0,80 14,81 1,04 0,90 14,74 1,04

1,00 14,67 1,05 1,10 14,59 1,06 1,20 14,52 1,06 1,30 14,45 1,07 1,40 14,37 1,07 1,50 14,30 1,08 1,60 14,23 1,08 1,70 14,15 1,09 1,80 14,08 1,09 1,90 14,01 1,10

2,00 13,93 1,11 2,10 13,86 1,11 2,20 13,79 1,12 2,30 13,71 1,12 2,40 13,64 1,13 2,50 13,57 1,14 2,60 13,49 1,14 2,70 13,42 1,15 2,80 13,35 1,15 2,90 13,27 1,16

3,00 13,20 1,17 3,10 13,13 1,17 3,20 13,05 1,18 3,30 12,98 1,19 3,40 12,91 1,19 3,50 12,83 1,20 3,60 12,76 1,21 3,70 12,69 1,21 3,80 12,61 1,22 3,90 12,54 1,23

O221

2max

2gem

–

2max

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

× %==

%CO

Air index

4,00 12,47 1,24 4,10 12,39 1,24 4,20 12,32 1,25 4,30 12,25 1,26 4,40 12,17 1,27 4,50 12,10 1,27 4,60 12,03 1,28 4,70 11,95 1,29 4,80 11,88 1,30 4,90 11,81 1,30

5,00 11,73 1,31 5,10 11,66 1,32 5,20 11,59 1,33 5,30 11,51 1,34 5,40 11,44 1,35 5,50 11,37 1,35 5,60 11,29 1,36 5,70 11,22 1,37 5,80 11,15 1,38 5,90 11,07 1,39

6,00 11,00 1,40 6,10 10,93 1,41 6,20 10,85 1,42 6,30 10,78 1,43 6,40 10,71 1,44 6,50 10,63 1,45 6,60 10,56 1,46 6,70 10,49 1,47 6,80 10,41 1,48 6,90 10,34 1,49

7,00 10,27 1,50 7,10 10,19 1,51 7,20 10,12 1,52 7,30 10,05 1,53 7,40 9,97 1,54 7,50 9,90 1,56 7,60 9,83 1,57 7,70 9,75 1,58 7,80 9,68 1,59 7,90 9,61 1,60

%CO

Air index

8,00 9,53 1,62 8,10 9,46 1,63 8,20 9,39 1,64 8,30 9,31 1,65 8,40 9,24 1,67 8,50 9,17 1,68 8,60 9,09 1,69 8,70 9,02 1,71 8,80 8,95 1,72 8,90 8,87 1,74

9,00 8,80 1,75 9,10 8,73 1,76 9,20 8,65 1,78 9,30 8,58 1,79 9,40 8,51 1,81 9,50 8,43 1,83 9,60 8,36 1,84 9,70 8,29 1,86 9,80 8,21 1,87 9,90 8,14 1,89

10,00 8,07 1,91 10,10 7,99 1,93 10,20 7,92 1,94 10,30 7,85 1,96 10,40 7,77 1,98 10,50 7,70 2,00 10,60 7,63 2,02 10,70 7,55 2,04 10,80 7,48 2,06 10,90 7,41 2,08

11,00 7,33 2,10 11,10 7,26 2,12 11,20 7,19 2,14 11,30 7,11 2,16 11,40 7,04 2,19 11,50 6,97 2,21 11,60 6,89 2,23 11,70 6,82 2,26 11,80 6,75 2,28 11,90 6,67 2,31

Page 88

O2, CO2, Lambda Conversion Table

Heavy Fuel Oil

Relation between O2 and CO2 value for heavy fuel oil (CO

2max

=15,9 %)

%CO

Air index

0,00 15,90 1,00 0,10 15,82 1,00 0,20 15,75 1,01 0,30 15,67 1,01 0,40 15,60 1,02 0,50 15,52 1,02 0,60 15,45 1,03 0,70 15,37 1,03 0,80 15,29 1,04 0,90 15,22 1,04

1,00 15,14 1,05 1,10 15,04 1,06 1,20 14,99 1,06 1,30 14,92 1,07 1,40 14,84 1,07 1,50 14,76 1,08 1,60 14,69 1,08 1,70 14,61 1,09 1,80 14,54 1,09 1,90 14,46 1,10

2,00 14,39 1,11 2,10 14,31 1,11 2,20 14,23 1,12 2,30 14,16 1,12 2,40 14,08 1,13 2,50 14,01 1,14 2,60 13,93 1,14 2,70 13,86 1,15 2,80 13,78 1,15 2,90 13,70 1,16

3,00 13,63 1,17 3,10 13,55 1,17 3,20 13,48 1,18 3,30 13,40 1,19 3,40 13,33 1,19 3,50 13,25 1,20 3,60 13,17 1,21 3,70 13,10 1,21 3,80 13,02 1,22 3,90 12,95 1,23

O221

2max

2gem

–

2max

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

× %==

%CO

Air index

4,00 12,87 1,24 4,10 12,80 1,24 4,20 12,72 1,25 4,30 12,64 1,26 4,40 12,57 1,27 4,50 12,49 1,27 4,60 12,42 1,28 4,70 12,34 1,29 4,80 12,27 1,30 4,90 12,19 1,30

5,00 12,11 1,31 5,10 12,04 1,32 5,20 11,96 1,33 5,30 11,89 1,34 5,40 11,81 1,35 5,50 11,74 1,35 5,60 11,66 1,36 5,70 11,58 1,37 5,80 11,51 1,38 5,90 11,43 1,39

6,00 11,36 1,40 6,10 11,28 1,41 6,20 11,21 1,42 6,30 11,13 1,43 6,40 11,05 1,44 6,50 10,98 1,45 6,60 10,90 1,46 6,70 10,83 1,47 6,80 10,75 1,48 6,90 10,68 1,49

7,00 10,60 1,50 7,10 10,52 1,51 7,20 10,45 1,52 7,30 10,37 1,53 7,40 10,30 1,54 7,50 10,22 1,56 7,60 10,15 1,57 7,70 10,07 1,58 7,80 9,99 1,59 7,90 9,92 1,60

%CO

Air index

8,00 9,84 1,62 8,10 9,77 1,63 8,20 9,69 1,64 8,30 9,62 1,65 8,40 9,54 1,67 8,50 9,46 1,68 8,60 9,39 1,69 8,70 9,31 1,71 8,80 9,24 1,72 8,90 9,16 1,74

9,00 9,09 1,75 9,10 9,01 1,76 9,20 8,93 1,78 9,30 8,86 1,79 9,40 8,78 1,81 9,50 8,71 1,83 9,60 8,63 1,84 9,70 8,56 1,86 9,80 8,48 1,87 9,90 8,40 1,89

10,00 8,33 1,91 10,10 8,25 1,93 10,20 8,18 1,94 10,30 8,10 1,96 10,40 8,03 1,98 10,50 7,95 2,00 10,60 7,87 2,02 10,70 7,80 2,04 10,80 7,72 2,06 10,90 7,65 2,08

11,00 7,57 2,10 11,10 7,50 2,12 11,20 7,42 2,14 11,30 7,34 2,16 11,40 7,27 2,19 11,50 7,19 2,21 11,60 7,12 2,23 11,70 7,04 2,26 11,80 6,97 2,28 11,90 6,89 2,31

Page 89

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 volume will cause the exhaust gas loss to rise. The exhaust gas loss can be calculated as follows:

Example: Data measured in natural gas mode: CO

content of exhaust gases 10,8%

Exhaust gas temperature 195°C Air intake temperature 22°C

The exhaust gas loss can be calcul ated as follows:

Data measured in fuel oil mode: CO

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:

= exhaust gas loss in %

= exhaust gas temperature

in °C

= combustion air temperature

in °C

= volumetric content of carbon

dioxide in %

tAtL–()

-----------

B+

⎠

⎞

⎝

⎛

⋅=

Light oil

Heavy oil

Natural

gas

Town

gas

L.P.G.

= 0,50 0,490 0,370 0,350 0,420

B = 0, 007 0,007 0,009 0,011 0 ,00 8

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.Is ther any gas pressure?

4.Are the shut-off valves opened?

5.Are all control and safety instruments 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 ignition 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-ventilating 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

Page 90

Trouble Shooting Instructions

8. Cleaning and lubricating instructions

Depending on the amount of dirt 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 moving 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; flame trouble.

Unlock and

search for cause

UV-Radiation too weak.

Check combus-

tion setting. Burner starts

without flame formation. Solenoid valve fails to open.

Defective coil or

rectifier.

Check connec-

tion.

Lack of gas or gas pressure too low.

Check gas pres-

sure controller,

gas valve, gas

filter.

Is the equip-

ment gas cock

open?

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

(oil operation) 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 f low 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.

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Customer Service:

ELCO GmbH

D - 64546 Mörfelden-Walldorf

ELCO Austria GmbH

A - 2544 Leobersdorf

ELCOTHERM AG

CH - 7324 Vilters

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NL - 1410 AB Naarden

ELCO Belgium n.v./s.a.

B - 1731 Zellik

ELCO Italia S.p.A

I - 31023 Resana (TV)

elco RPD 30, RPD 40, RPD 50, RPD 70, RPD 80 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual