Olympia LT-80, LT-150, LT-100, LT-250, LT-400 Operating Manual

OLYMPIA BURNER

OPERATING MANUAL

MODEL: LT-40,45,60,80,100,120,150,

200,250,300,400,500,600,700

OLYMPIA INDUSTRIAL CO., LTD.

CONTENT

1. INTRODUCTION OF PRODUCT.

1) BURNER SPECIFICATION.

2) COMBUSTION PERFORMANCE GRAPH.

3) SIZE AND DIMENSION.

4) EXPLODED DRAWING OF BURNER AND PART NAME.

2. HOW TO CONTROL BURNER.

1) BURNER COMBUSTION FURNACE DIMENSION.

2) HOW TO INSTALL BURNER.

3) DIAGRAM OF FUEL CIRCULATION SYSTEM.

4) HOW TO INSTALL FUEL PIPE SYSTEM.

5) TIME CHART.

6) ELECTRIC CIRCUIT DIAGRAM.

3. HOW TO USE MAJOR PARTS.

1) COMBUSTION HEAD DIMENSION.

2) HOW TO ADJUST COMBUSTION OF AIR FLOW RATE.

3) HOW TO DISASSEMBLE, CLEAN AND REPLACE NOZZLE.

4) FLAME DETECTOR.

5) GEAR PUMP.

6) IGNITION TRANSFORMER.

7) FUEL FILTER.

4. GENERAL BURNER OPERATION.

5. HOW TO CHECK BURNER, CAUSE OF TROUBLE AND COUNTER MEASURE.

1) CHECK OF BURNER.

2) BURNER TROUBLE/ACTION TABLE.

3) CAUSE OF COUNTER-MEASURE ACTION.

MOD EL

FUEL

MIN/ MAX(kg/

h)

CONTROL

VOLTAGE

(V)

MOT OR

(60㎐ /kW)

GEAR
PUM P

OIL HOSE

MOT OR
POW ER

INHALATION

380V

RETURN

220V

LT-40U

20~40

HI-L OW-OFF

AC3φ220/38

0

O.45

AS47A

PT 1/4"
PT 1/4"

1.2

2.1

LT-40UH

20~40

LT-45U

20~45

0.75

PT 3/8"
PT 1/4"

1.7

3.0

LT-45UH

20~45

LT-60U

25~54

1.1

AN-77

2.4

4.1

LT-60UH

25~54

LT-80U

34~68

LT-80T

34~68

HI-L OW-OFF

or

MODURATING

LT-100

30~98

HI-L OW-OFF

1.5

AJ-6

PT 3/8"
PT 3/8"

3.3

5.7

LT-120

51~123

HI-L OW-OFF

or

MODURATING

2.2

LT-150T

60~150

HI-M ID-LO W-O

FF

or

MODURATING

3.0

4.7

8.2

LT-200T

65~200

HI-M ID-LO W-O

FF

or

MODURATING

4.0

7.5

13.0

LT-250T

71~214

HI-M ID-LO W-O

FF

or

MODURATING

5.5

E-7

11.8

20.4

LT-300T

80~250

7.5

TA-2

PT 1/2"
PT 1/2"

15.8

27.3

LT-400T

108~ 330

11

20.4

35.5

LT-500T

136~ 408

11

20.4

35.5

LT-600T

194~ 583

15

20.4

35.5

LT-700T

167~ 668

18.5

20.4

35.5

1. INTRODUCTION OF PRODUCT.

LT-Series oil Burner is also designed and manufactured upon our well experienced technique
and is made of motor, oil pump, fan, ignition equipment and automation in single body.
the highly pressurized fuel particulates are perfected burnt, which minimizes smoke it has
following benefits.

■ it is easy to check and maintain as a hinge type.

■ All the automatic devices are assembled in an integrated method.

■ it can operate both automatically. emergency operation is possible when the
automatic device is out of order.

1) BURNER SPECIFICATION.

2）COMBUSTION PERFORMANCE GRAPH.

3) SIZE AND DIMENSION.

① LT-40,45,60 DIMENSION

② LT-80,100,150,200,250,300,400,500,600,700 DIMENSION

◉

LT-series burner is an hydraulic gun type burner with forced flue fan.
the ignition rate is controlled as follows depending on the number of nozzle.
․ two nozzle: 2-position control( hi-low-off)
․ three nozzle: 3-position control(hi-mid-low-off)
one proportional nozzle: proportional control(modulating)
◉ how to control air flow rate.
․ two nozzle: damper motor or hydraulic cylinder type
․ three nozzle: damper motor type ․ one proportional nozzle: modulating motor type

4) EXPLODED DRAWING OF BURNER AND PART NAME.
(1) LT-40U,45U,60U BURNER EXPLODED DRAWING.

(2) LT-40UH,45UH,60UH BURNER EXPLODED DRAWING.

(3) LT-80U,100U,150,200,250,300,400,500,600,700 BURNER EXPLODED DRAWING.

* LT-80T,100T,150,200,250,300 = DAMPER MOTOR

LT-250,300,400,500,600,700 = 3NOZZLE

MODEL

LT-40

LT-45,60

LT-80,100

LT-150,200

LT-250,300

LT-400,500,600,700

A

150

171

190

234

270

310

340

380

400

434

B

155

175

195

240

275

315

345

385

405

440

C

160

160

350

290

400

400

D

228

228

315

350

430

430

E

M10

M10

M14

M14

M16

M16

2. HOW TO CONTROL BURNER

1) BURNER COMBUSTION FURNACE DIMENSION

2) HOW TO INSTALL BURNER.

(1) burner assembly sequence(refer to above sketch)

① insert gasket into the burner hinge. insert burner to the boiler fire outlet or
combustion furnace, and tightly fasten.
② after adjusting the burner in the hinge, fix the burner with hinge pin.

(2) caution during burner installation

① make it sure to install burner horizontally.
② fasten bolts tightly so that no combustion gas leaks.
③ after installing the hinge-type burner, use care so that no part of ignition bar is
damaged or deformed during assembly of frame.
④ secure enough working space to check and maintain burner.
․ flange tube type burner: LT-40U ~ LT700T.
․ hinge tube type burner: LT-40UH ~ LT-60UH.

3) DIAGRAM OF FUEL CIRCULATION SYSTEM.

4) HOW TO LAY FUEL PIPE
the installation of the fuel pipe system for the gun type oil burner is divided into
single type pipe installation using the height of oil tank and dual type pipe installation
using sucking power of burner pump.

▶ cautions on laying fuel pipe
① on laying one pipe, it is important to remove by-pass plug, and when laying to
pipes, it must install by-pass plug.
② when oil tank is below burner, "H" its height must be less then 2.4m.
③ the inlet hole should place at 20cm higher then the floor of oil tank in order not
to flow in foreign subtainces.
④ it is recommended that oil pipe be welded in order not to flow in air.
⑤ in case of fixing several pipes, inlet and return pipe must use an enough space
pipe in inside diameter.
⑥ return pipe had better not use valve.(if operates return pipe with clogged states,
it may cause to damage pump and filter.)
⑦ the fuel filter must be used at inlet pipe and fix it with confirming the flowing
direction.

5) TIME CHART

(6) ELECTRIC CIRCUIT DIAGRAM.

* MODURATING TYPE

3. HOW TO USE MAJOR PARTS.

1) COMBUSTION HEAD DIMENSION.

◉ in case of adjusting "C" size, be careful not to touch the and of ignition bar with
diffuser or diffuser is not stained with oil.

2) HOW TO ADJUST COMBUSTION AIR FLOW RATE.
(1) hydraulic cylinder.
① structure

DM-310

DM-320

② how to adjust

ⓐ

first stage(low combustion) air adjustment : loosen the nut A, and adjust the
damper opening B for normal combustion.
then fully tighten the nut A.

ⓑ second stage(high combustion) air adjustment : loosen the nut D in the high
combustion mode, and tighten adjuster nut C to increase air flow rate until no
smoke coming out from the chimney, when adjustment is over, fully tighten
the nut D so that the adjuster nut is not loosened.

(2) damper motor.

① structure

② electric circuit diagram

③ how to adjustment damper
damper gauge consists of from "0"to"10", "0" indicates complete close and
"10"indicates complete open .
㉠ disconnect power.
㉡ adjust each CAM by deciding the position depending on the combustion rate.

ex) low combustion damper open : 2/10 open.
medium combustion damper open : 4/10 open.
high combustion damper open : 6/10 open.
ⓐ see each CAM of the damper open scale. accord with marked CAM scale
according to the setting position.
ⓑ when adjustment is over, and adjust damper plate to the low combustion
damper opening using the knob on the opposite side of the motor.
㉢ turn on the power. and adjust damper again while reviewing the operating
conditions of combustion. in this case make it sure to confirm that each switch
turns off sequentially from the low combustion damper CAM.
㉣ overrun protection s/w
when low or high combustion damper CAM is mistakenly adjusted.(for example,
low combustion damper CAM is set below zero in the damper scale or high
combustion damper CAM is set adove 10 in the damper scale) or when the low
or high combustion damper s/w is out of order. press the overrun protection s/w
to stop damper operation.
ⓐ when pressing the low overrun protection s/w.
readjust the low combustion damper CAM when the s/w is out of order,
replace the s/w. when it is completely closed, use the manual adjuster knob
to set in ti the low combustion opening position.
ⓑ when pressing the high overrun protection s/w.
readjust the high combustion damper CAM when the s/w is out of order,
replace the s/w.

3) HOW TO DISASSEMBLE, CLEAN AND REPLACE NOZZLE.
① the nozzle sprays fuel through fine hole(㉠)
② air flow rate and pump pressure are adjustable per the capacity of nozzle which is
specified in terms of spray rate, angle and patten.
③ capacity
G/H (gallon/hour): the capacity id specified as to consume 3.785 liters of
kerosene per hour under the pressure of 7㎏/㎠.
④ 80°: fuel is sprayed from nozzle hole in 80 degree angle.
⑤ when burning conditions are not satisfactory bue to inappropriate splay of fuel,
remove, disassemble and clean nozzle using kerosene.
a) how to replace nozzle.
ⓐ disconnect power.
ⓑ pull out one side of hinge pin to open the burner flame.
ⓒ hold nozzle adapter with spanner, and loosen nozzle counter clockwise.
ⓓ after changing nozzle, check and adjust the place of ignition by with referring to
assembling dimension of combustion head.
ⓔ replace nozzle in the reverse order.

◉

in the burner model LT40UH, LT45UH, LT60UH separate burner from the furnace.
then also separate the flange tube, and follow the adove procedure for
replacement.

b) how to disassemble and check nozzle

① separate filter (㉣). clean the filter using kerosene.
② separate the gelical support (㉢) using a screwdriver. clean the groove (㉡) using
kerosene and thin wire. do not use iron wire or needle. otherwise the nozzle hole
may widen.
③ after the nozzle hole is clean, assemble nozzle in the reverse order.
◉ make it fasten it set up.

4) FLAME DETECTOR.

① the flame detector detects the igniting
conditions of burner. when it detects that
ignition fails, it stop burner operation as a
safety device.
② when burner stops operation in several
seconds after burner ignitions, check
whether there is a soot or dust on the flame
sensor of the flame detector. thoroughly
remove soot or dust from the flame sensor if
any.

◉ if soot or dust is accumulated on the flame sensor of the flame detector, burner
stops operation. therefore it is required to clean the flame sensor using clean dry
cloth every month.

5) GEAR PUMP.

(1) external drawing and specification.

burner model

LT-40U,40UH

LT-45U~LT-200T

LT-200M~LT-250M

LT-250T~700T

pump model

AS&VM TYPE

AJ TYPE

E TYPE

TA TYPE

pump capacity(2850rpm)-ℓ/h

33~47

40~205

110~350

310~750

output pressure-bar

7~14

10~30

14~30

7~40

max. inlet pressure-bar

223.5

5

max. return pressure-bar

223.5

5

max. suction height-bar

0.45

0.45

0.45

0.45

max. rotational speed-rpm

3600

3600

3600

3600

* MODURATING- E TYPE.
(2) how to control.
① function: being connected motor and coupling, it intakes nozzle with adding
necessary pressure for combustion.
② how to adjust pressure: turning the(-)groove in the pressure adjuster hole
clockwise/counter clockwise, pressure is increasing/decreasing.
(3) how to purge air from the pump
① turn the gear pump air purge bolt counterclockwise 3 to 4 times with spanner,
operate burner. then air bubble comes through the air exhaust hole of the gear
pump. then clean oil discharges. then stop burner operation, and fully tighten
the air purge bolt. then operate burner.
② if air is not completely removed within 16 seconds, burner stops operation. when
pressing re-start button, burner resumes operation. when air is completely
removed after repeating this procedure, burner will operates normally.
◉ then completely tighten the air purge bolt with spanner.

6) IGNITION TRANSFORMER

① external drawing

② function
it is an ignition to raise input voltage from 220V to 17Kv and outputs the raised
voltage to the ignition bar for a normal burner operation.
◉ if the ignition transformer is in trouble, no ignition occurs.

P O W E R

automatic operation

manual operation

burner s/w turns on

burner s/w turns on

auto/man s/w : auto

auto/man s/w : manual

lock release

inter lock release

blower/gear pump operate

blower/gear pump/ ignition transformer operation

operation of ignition bar

low combustion s/w : on

low combustion valve : on

high combustion s/w : on

flame detecter check the ignition

hydraulic cylinder or damper motor operates

hydraulic cylinder or damper motor operates

safety device does not operate in the manual mode,

use manual mode for emergency operation only.

continue to check conditions of flame during manual

operation

high combustion valve : on

automatic operation by inter lock

☞ auction: take care of the ignition transformer as high voltage is applied to the
ignition transformer.

7) FUEL FILTER.

▶ how to handle fuel filter
․ the fuel filter removes foreign
substance from fuel.
․ when burner does not generate
flame as no fuel is fed even if
oil pipe is contained in the fuel
tank, clean the fuel filter.
․ when fulling out a container ③
below the plastic cap①, you
find a filter② in the container.
․ clean the filter using kerosene

or light oil, replace filter.

◉ fully tighten the filter to prevent penetration of air after cleaning the filter.

4. GENERAL BURNER OPERATION

5. HOW TO MAINTAIN, CHECK AND SERVICE BURNER.

1) CHECK OF BURNER.
▶ check the followings prior to burner operation.
① after checking the water level of boiler, pressure and fuel feed rate, open the
valve between tank and oil pump.
② check whether the working voltage and fuel meet the burner specification.
③ discharge air from the fuel pipe system.
④ check whether or not the burner nozzle corresponds the boiler or furnace
capacity..

▶ maintenance of burner
① clean the ignition bar if it is contaminated.
② clean nozzle and nozzle adapter.
③ if soot is accumulated on the diffuser, burner fails to ignite.
remove the soot from the diffuser.
④ check and clean oil filter if required.
⑤ check and clean flame detector if required.

2) BURNER TROUBLE/ACTION TABLE

3) CAUSE OF TROUBLE AND COUNT-MEASURE ACTION

trouble

major cause

action

motor does not
operate.

1. flame sensor detects danger.
signal, and stops operation.

2. protector relay is out of order.

3. motor is out of order.

4. gear pump is out of order.

․ reset after removing
the cause of trouble.

․ replace and repair.
․ replace and repair.
․ replace and repair.

motor operates but
does not ignite.

1. ignition bar is inaccurately
adjusted or damaged.

2. transformer or lead wire is out of order.

3. pump discharge pressure drops and air
suction.

4. no oil is sucked in.

5. electronic valve is clogged or out of
order.

6. combustion air flow rate is too much or
less.

7. nozzle is clogged.

8. inlet pipe is damaged.

9. coupling is poor.

․ adjust ignition bar
position and replace.

․ replace and repair.
․ raise discharge.

pressure discharge air.
․ check valve and clean
filter.

․ replace and repair.
․ adjust damper.

․ replace and repair.
․ replace and repair.
․ replace and repair.

when combustion
stop immediately
after ignites.

1. flame sensor is contaminated.

2. flame sensor is out of order

3. protector relay is out of order.

․ clean
․ replace and repair.
․ replace and repair.

combustion is
unstable or smoke
occurs.

1. hydraulic pressure is inappropriate for
spray.

2. nozzle is clogged

3. combustion air flow rate is too much or
less.

․ adjust spray pressure.

․ replace and repair.
․ adjust damper.

in case of
operated by
manual but no
operated by
automatic.

1. protect relay is out of order.

2. protection of protect relay reset button

3. flame sensor receiving light from out
side

․ change or repair.
․ reset after removing

the cause of trouble
․ reset after removing
the cause of trouble

flame is red.

1. short of air.

․ open damper.

flame is blue and
white

1. combustion air flow rete is too much

․ close damper