elco RPD 30, RPD 40, RPD 50, RPD 70, RPD 80 Operation Manual
...
Operation Manual
For the authorized specialist
Dual-fuel Duoblock Burner
RPD 30 - 100 GL-R / GS-R
03/2005 102.877.8447
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
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
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
0
2000
4000
6000
8000
10000
12000
RPD 30 RPD 40 RPD 50
kW
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
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.
G
D2
22,5 °
P
4
P
3
X
P1
P2
Y
Z
B1
T1
444
B2
RPD 20 - 60
H
2
H
3
H
1
D1
H
4
T
2
T
3
V
D7
A1
D2
D
4
D
5
1
0
0
%
D
6
5
0
%
L6 50%
L4 100%
B3 B4 B5W
RPD 70 - 100
D2
Gewinde
Länge K
Stift M
D3
D3
Bohrungen Kesselplatte
B6
22,5 °
B8
15°
15°
L5L1
T
U
R
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
6
Technical Data Sheet
Duoblock Dual Fuel Burner
Feld52:
RPD 60 / 70 / 80 GL-R / GS -R
145 11
20470
30350
2232
3590
5500
0
5000
10000
15000
20000
25000
30000
35000
RPD 60 RPD 70 RPD 80
kW
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
7
D
4
L6 50%
G
L4 100%
RPD 20 - 60
P1
P2
Y
B1
444
X
Z
T1
B2
P
4
P
3
H
2
D1
H
3
H
4
T
2
T
3
V
D7
A1
D2
D
5
1
0
0
%
D
6
5
0
%
H
1
B3 B4 B5W
15°
D2
D3
15°
B6
D2
Stift M
Gewinde
Länge K
D3
B8
Bohrungen Kesselplatte
22,5 °
22,5 °
RPD 70 - 100
U
L1
R
T
L5
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
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 secondary 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.
set screw M
length K
Details of boiler front plate
8
Technical Data Sheet
Duoblock Dual Fuel Burner
Feld52:
RPD 90 / 100 GL-R / GS-R
42000
45000
7000 7000
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
RPD 90 RPD 100
kW
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
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
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 secondary 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.
D
4
L6 50%
G
L4 100%
RPD 20 - 60
P1
P2
Y
B1
444
X
Z
T1
B2
P
4
P
3
H
2
D1
H
3
H
4
T
2
T
3
V
D7
A1
D2
D
5
1
0
0
%
D
6
5
0
%
H
1
B3 B4 B5W
15°
D2
D3
15°
B6
D2
Stift M
Gewinde
Länge K
D3
B8
Bohrungen Kesselplatte
22,5 °
22,5 °
RPD 70 - 100
U
L1
R
T
L5
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
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
12
11
4 17 16 15
5 6 29,30 7 32
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
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.
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
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% *)
20
530 53 29 90 314 91 560 325 530 500 270 260 210 - 12 250 385 265 650 425 30 465 - 68 780
30
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
40
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
50
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
60
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
70
1160 78 19 315 375 75 765 731 1240 1200 640 626 520 565 18 469 780 580 1360 900 30 740 - 170 1995
80
1350 75 19 315 375 75 765 860 1450 1400 740 710 597 646 18 600 820 675 1495 1000 30 700 - 185 2285
90
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% *) ***)
20
- 10 430 510 236 316 - - - 112 150 240 -
18x1,5
50 190
2x1 43 4x1 20
10
30
62 12 580 670 320 410 1265 140 497 160 192 491 346
22x1 ,5
80 248
4x92 5x1 26
10
40
50 12 580 670 320 410 1265 140 497 160 192 491 346
22x1 ,5
80 248
4x92 5x1 26
10
50
55 12 740 830 416 506 1743 115 595 181 250 530 376
22x1 ,5
125 319
3x1 52 5x1 56
10
60
62 12 750 840 470 560 1760 195 622 181 270 555 401
22x1 ,5
125 379
4x1 29 5x1 60
10
70
85 12 936 102 6 600 690 2010 270 705 181 365 610 450
28x1 ,5
125 410
5x1 28 7x1 40
10
80
92 12 1102 1192 700 790 2320 310 800 187 310 707 495
28x1 ,5
200 489
6x1 25 9x1 28
10
90
- 12 1300 1390 742 8 32 2720 240 845 224 310 832 620
28x1 ,5
200 494
6x1 32 10x 135
10
100
- 12 1300 1390 742 8 32 2720 240 845 224 310 832 620
28x1 ,5
200 494
6x1 32 10x 135
10
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
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
17
Hydraulic Scheme
RPD 30 -50
Oil Control Block and Nozzle Rod DG 75
11
12
12
14
14
16
16
13
15
8
10
9
7
6
5
4
3
2
1
11
12
12
14
14
16
16
13
15
8
10
9
7
6
5
4
3
2
1
11
12
12
14
14
16
16
13
15
8
10
9
7
6
5
4
3
2
1
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
18
Hydraulic Scheme
RPD 30 -100
Oil Control Block and Nozzle Rod MAT
11
12
12
14
14
14
14
16
16
15
17
17
17
17
13
10
9
7
6
5
4
3
2
1
11
12
12
10
9
7
6
5
4
3
2
1
14
14
14
14
1616
15
13
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
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
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
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.
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).
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.
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
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.
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.
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.
0
1
2
3
4
5
100 110 120 130 140 150 160
Temperatur °C
Druck bar
Temperature °C
Pressure bar
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
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
Temperature: Max. 80°C
Supply pressure: Max. 0.5 bar
Axial face seal
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