Technical Documentation CIB Unigas - Campodarsego (PD - Italy)

INDUSTRIAL BURNER MODEL

URB 4CLIENT:

DESCON ENGINEERINGPROJECT 00P270

M09

973C

A Re

v. 00

12/

00

NOTICES2

NOTICESTHIS MANUAL IS SUPPLIED AS AN INTEGRAL AND ESSENTIAL PART OF THE PRODUCT AND MUST BE DELIVERED TO THE USER.INFORMATION INCLUDED IN THIS SECTION ARE DEDICATED BOTH TO THE USER AND TO PERSONNEL FOLLOWING PRODUCT INSTALLATION AND MAINTENANCE.THE USER WILL FIND FURTHER INFORMATION ABOUT OPERATING AND USE RESTRICTIONS, IN THE SECOND SEC-TION OF THIS MANUAL. WE HIGHLY RECOMMEND TO READ IT.CAREFULLY KEEP THIS MANUAL FOR FUTURE REFERENCE.

1) GENERAL INTRODUCTIONThe equipment must be installed in compliance with the regu-lations in force, following the manufacturers instructions, byqualified personnel.Qualified personnel means those having technical knowledgein the field of components for civil or industrial heatingsystems, sanitary hot water generation and particularly ser-vice centres authorised by the manufacturer.Improper installation may cause injury to people and animals,or damage to property, for which the manufacturer cannot beheld liable.* Remove all packaging material and inspect the equipmentfor integrity.In case of any doubt, do not use the unit - contact the supplier.The packaging materials (wooden crate, nails, fastening devi-ces, plastic bags, foamed polystyrene, etc), should not be leftwithin the reach of children, as they may prove harmful.* Before any cleaning or servicing operation, disconnect theunit from the mains by turning the master switch OFF, and/orthrough the cut-out devices that are provided.* Make sure that inlet or exhaust grilles are unobstructed.* In case of breakdown and/or defective unit operation,disconnect the unit. Make no attempt to repair the unit or takeany direct action.Contact qualified personnel only.Units shall be repaired exclusively by a servicing centre, dulyauthorised by the manufacturer, with original spare parts.Failure to comply with the above instructions is likely to impairthe units safety.To ensure equipment efficiency and proper operation, it isessential that maintenance operations are performed by quali-fied personnel at regular intervals, following the manufactu-rers instructions.* When a decision is made to discontinue the use of the equi-pment, those parts likely to constitute sources of danger shallbe made harmless.* In case the equipment is to be sold or transferred to anotheruser, or in case the original user should move and leave theunit behind, make sure that these instructions accompany theequipment at all times so that they can be consulted by thenew owner and/or the installer.* For all the units that have been modified or have options fit-ted then original accessory equipment only shall be used.* This unit shall be employed exclusively for the use for whichit is meant. Any other use shall be considered as improperand, therefore, dangerous.The manufacturer shall not be held liable, by agreement orotherwise, for damages resulting from improper installation,use and failure to comply with the instructions supplied by themanufacturer.

2) SPECIAL INSTRUCTIONS FOR BURNERS*The burner should be installed in a suitable room, with venti-lation openings complying with the requirements of the regu-lations in force, and sufficient for good combustion.* Only burners designed according to the regulations in forceshould be used.* This burner should be employed exclusively for the use forwhich it was designed.* Before connecting the burner, make sure that the unit ratingis the same as delivery mains (electricity, gas oil, or otherfuel).*Observe caution with hot burner components. These are,usually, near to the flame and the fuel pre-heating system,they become hot during the unit operation and will remain hotfor some time after the burner has stopped.* When the decision is made to discontinue the use of the bur-ner, the user shall have qualified personnel carry out the fol-lowing operations:a) Remove the power supply by disconnecting the power cordfrom the mains.b) Disconnect the fuel supply by means of the hand-operatedshut-off valve and remove the control handwheels from theirspindles.Special warnings* Make sure that the burner has, on installation, been firmlysecured to the appliance, so that the flame is generated insidethe appliance firebox.* Before the burner is started and, thereafter, at least once ayear, have qualified personnel perform the following opera-tions:a) set the burner fuel flow rate depending on the heat input ofthe appliance;b) set the flow rate of the combustion-supporting air to obtaina combustion efficiency level at least equal to the lower levelrequired by the regulations in force;c) check the unit operation for proper combustion, to avoidany harmful or polluting unburnt gases in excess of the limitspermitted by the regulations in force;d) make sure that control and safety devices are operatingproperly;e) make sure that exhaust ducts intended to discharge theproducts of combustion are operating properly;f) on completion of setting and adjustment operations, makesure that all mechanical locking devices of controls have beenduly tightened;g) make sure that a copy of the burner use and maintenanceinstructions is available in the boiler room.* In case of repeated burner shut-downs, do not continue re-setting the unit manually. Contact qualified personnel to takecare of such defects.* The unit shall be operated and serviced by qualified person-nel only, in compliance with the regulations in force.

NOTICES 3

3) GENERAL INSTRUCTIONS DEPENDING ON FUEL USED 3a) ELECTRICAL CONNECTION* For safety reasons the unit must be efficiently earthed andinstalled as required by current safety regulations.* It is vital that all saftey requirements are met. In case of anydoubt, ask for an accurate inspection of electrics by qualifiedpersonnel, since the manufacturer cannot be held liable fordamages that may be caused by failure to correctly earth theequipment.* Qualified personnel must inspect the system to make surethat it is adequate to take the maximum power used by theequipment shown on the equipment rating plate. In particular,make sure that the system cable cross section is adequate forthe power absorbed by the unit.* No adaptors, multiple outlet sockets and/or extension cablesare permitted to connect the unit to the electric mains.An omnipolar switch shall be provided for connection tomains, as required by the current safety regulations.The use of any power-operated component impliesobservance of a few basic rules, for example:- do not touch the unit with wet or damp parts of the body and/or with bare feet;- do not pull electric cables;- do not leave the equipment exposed to weather (rain, sun,etc.) unless expressly required to do so;- do not allow children or inexperienced persons to use equip-ment;* The unit input cable shall not be replaced by the user.In case of damage to the cable, switch off the unit and contactqualified personnel to replace.* When the unit is out of use for some time the electric switchsupplying all the power-driven components in the system (i.e.pumps, burner, etc.) should be switched off.

3b) FIRING WITH GAS, GASOIL OR OTHER FUELSGENERAL* The burner shall be installed by qualified personnel and incompliance with regulations and provisions in force; wronginstallation can cause injuries to people and animals, ordamage to property, for which the manufacturer cannot beheld liable.* Before installation, it is recommended that all the fuel supplysystem pipes be carefully cleaned inside, to remove foreignmatter that might impair the burner operation.* Before the burner is commissioned, qualified personnelshould inspect the following:a) the fuel supply system, for proper sealing;b) the fuel flow rate, to make sure that it has been set basedon the firing rate required of the burner;c) the burner firing system, to make sure that it is supplied forthe designed fuel type;d) the fuel supply pressure, to make sure that it is included inthe range shown on the rating plate;e) the fuel supply system, to make sure that the systemdimensions are adequate to the burner firing rate, and that thesystem is equipped with all the safety and control devicesrequired by the regulations in force.* When the burner is to remain idle for some time, the fuelsupply tap or taps should be closed.SPECIAL INSTRUCTIONS FOR USING GAS* Have qualified personnel inspect the installation to ensurethat:a) the gas delivery line and train are in compliance with theregulations and provisions in force;b) all gas connections are tight;c) the boiler room ventilation openings are such that theyensure the air supply flow required by the current regulations,and in any case are sufficient for proper combustion.* Do not use gas pipes to earth electrical equipment.* Never leave the burner connected when not in use. Alwaysshut the gas valve off.* In case of prolonged absence of the user, the main gas deli-very valve to the burner should be shut off.Precautions if you can smell gasa) do not operate electric switches, the telephone, or anyother item likely to generate sparks;b) immediately open doors and windows to create an air flowto purge the room;c) close the gas valves;d) contact qualified personnel.* Do not obstruct the ventilation openings of the room wheregas appliances are installed, to avoid dangerous conditionssuch as the development of toxic or explosive mixtures.

4CONTENTSWINDBOX AND REGISTER ASSEMBLY ................................................................................................................. 7INSTALLATION ......................................................................................................................................................... 7ADJUSTMENT OF AIR PRESSURE SWITCH .......................................................................................................... 7ELECTRIC CONTROL BOX INSTALLATION .......................................................................................................... 8REFRACTORY TILE .................................................................................................................................................. 10PILOT BURNER ........................................................................................................................................................ 11ADJUSTMENTS ........................................................................................................................................................ 11ADJUSTMENT OF GAS PRESSURE GOVERNOR ................................................................................................. 11ADJUSTMENT OF GAS PRESSURE SWITCH ........................................................................................................ 11MAIN GAS TRAIN ..................................................................................................................................................... 12ADJUSTMENTS ........................................................................................................................................................ 12OIL PUMPING UNIT .................................................................................................................................................. 13ADJUSTMENTS ........................................................................................................................................................ 13ADJUSTMENT OF OIL PRESSURE SAFETY VALVE ............................................................................................. 13MAINTENANCE ......................................................................................................................................................... 13OIL FILTER CLEANING ............................................................................................................................................ 13OIL HEATING UNIT ................................................................................................................................................... 14ADJUSTMENTS ........................................................................................................................................................ 15ADJUSTMENT OF OIL TEMPERATURE REGULATOR .......................................................................................... 15ADJUSTMENT OF OIL TEMPERATURE SWITCHES ............................................................................................. 15MAINTENANCE ......................................................................................................................................................... 15STEAM FILTER CLEANING ..................................................................................................................................... 15OIL HANDLING UNIT ................................................................................................................................................ 16ADJUSTMENTS ........................................................................................................................................................ 17OIL PRESSURE SETTING ........................................................................................................................................ 17OIL PRESSURE SWITCH SETTING (PO min.) ........................................................................................................ 17OIL THERMOSTAT SETTING ................................................................................................................................... 17STEAM PRESSURE SETTING ................................................................................................................................. 17MAINTENANCE ......................................................................................................................................................... 17STEAM FILTER CLEANING ..................................................................................................................................... 17DIFFUSER POSITION ............................................................................................................................................... 18NOZZLE POSITION ................................................................................................................................................... 18BURNER FAMILIARIZATION AND INSPECTION .................................................................................................... 19PRELIMINARY INSPECTION .................................................................................................................................... 19SUGGESTED INSTALLATION INSPECTION CHECKLIST GENERAL .................................................................. 19GAS FIRING .............................................................................................................................................................. 19OIL FIRING ................................................................................................................................................................ 19OPERATING SEQUENCE ......................................................................................................................................... 20GAS MODE ................................................................................................................................................................ 20OIL MODE .................................................................................................................................................................. 20FIRING CHANGE FROM LANCE n 1 TO LANCE n 2 ........................................................................................... 20TROUBLESHOOTING GUIDE .................................................................................................................................. 21SPARE PART LIST .................................................................................................................................................... 25

51 GENERAL DESCRIPTION OF THE SYSTEMThe forced draft burner combines the advantages of the proven register, windbox and fan to supply 100% of combustion air inone complete package. Combustion controls, safety controls, fuel trains with all valving prepiped and wired are an integral partsof the burner package.Burner mounting and installation time is minimised. Component operation is checked and tested at the factory prior to shipment.Package systems are available for heat requirements that range from 10.000 kW to 60.000 kW.ApplicationThe package burner combustion systems engineered for application to package or field erected boilers and heaters. These for-ced draft burners can be adapted to the firing of air heaters and dryers. The high turndown efficient forced draft package burne rcan replace multiple burners on many boiler or heater conversions, resulting in improved operating efficiencies.The package burner modular design permits utilisation of existing power plant equipment such as blowers, combustion air pre-heaters, boiler feedwater controls, draft controls and annunciators. On boilers with extremely wide furnaces, multiple burnerscan be incorporated in a single package system. The package burner system can be utilised for both vertical and horizontalfiring.FuelsThe forced draft package burners can be supplied for single fuels for gas or oil firing, as well as simultaneous firing of multiplefuels.Steam atomisation for oil firing is standard. Air atomisation is an available option.Combustion Safety ControlsThe forced draft package burners safety control system provides continuous monitoring of the firing operation. A pre-purge ofadequate air changes occurs followed by safe pilot and mainflame ignition at the minimum fire position.Components of the safeguard system are factory assembled, wired and tested and enclosed in a suitable enclosure required forthe particular burner environment. The control cabinet assembly is factory mounted on the burners. All burner mountedcomponents are factory wired to the control cabinet and the complete assembly is factory tested as a unit.Combustion Fuel-Air ControlsThe standard forced draft package burners include an electrical self-contained master steam pressure controller. This controlleris in direct contact with the boiler steam pressure that is to be maintained. A change in steam pressure immediately results in acorresponding change of fuel-air input to the burner necessary to maintain a constant steam pressure on the boiler. Standardcontrol mode is automatic. The burner firing rate can also be adjusted manually from a remote manual control station locatedin the burner control cabinet, when so desired. The system is a single point positioning system utilising a common jackshaftwhich, in turn, is directly connected to characterisable fuel control valves and forced air volume dampers.Parallel positioning combustion control systems are also available. A common master controls a fuel controller and air control-ler.These controllers operate an air volume controller and a fuel volume controller. With this system, the forced draft fan can belocated at a distance from the burner. Manual-automatic stations are provided for manual operation of the system. Programsolenoid valves are included to provide automatic operation.Which follows is a typical burner assembly.

6Fig. 1 - TYPICAL BURNER ASSEMBLY - Key1 OIL GUN SUPPORT2 OCTAGONAL FRONTPLATE3 BUSH4 REGISTER ASSEMBLY5 WINDBOX6 REGISTER RING7 REFRACTORY TILE8 PILOT BURNER

9 DIFFUSER CONE10 GAS PORTS11 REFRACTORY TILE RING12 BOILER PLATE13 GAS RING14 SPACER SPOOL ASSEMBLY15 REGISTER LOUVER16 OIL GUN ASSEMBLY

72 WINDBOX AND REGISTER ASSEMBLYThe forced draft package burner windbox is constructed of heavy gauge welded steel. Burner registers are mounted in the win-dbox to permit easy access for maintenance.Balanced air distribution in the windbox assures optimum mixing of fuels with turbulent air.Insulated windboxes for use with pre-heated combustion air are available. Fuel piping trains and associated hardware aremounted on self-supporting frames welded to the burner windbox.The burner and combustion system presents a compact, economical and attractive assembly.Basically two types of burner registers can be included in the package burner assembly.2.1 INSTALLATIONThe steel structure has to be put in the right position providing to avoid any damaging to the accessories installed on it, forinstance piping, pressure switches, valves, or other projecting items.The windbox is supplied with a steel flange to be fixed to the boiler according to the delivered drawings different for each size.The installation has to be done according to all the relevant safety rules. A good installation guarantees a long life to the burner.

2.2 ADJUSTMENT OF AIR PRESSURE SWITCHAlways follow manufacturer instructions for detailedprocedures.Pressure switches are electric devices opening orclosing safety contacts when air pressure is too highor too low.The initial value must be set to 10 mbar.

ADJUSTING WHEEL

Fig. 2

83 ELECTRIC CONTROL BOX INSTALLATIONIt has to be installed in order to:!!!! Provide a good ventilation!!!! Avoid any heating!!!! Avoid any vibrations!!!! Be water and dust proofRemember to ground the steel structure!

Fig. 3 - ELECTRIC BOX Fig. 3a - CONTROL PANEL

9CONTROL PANEL - Complete KeyCL- Fan motor contactor - lineCM- Manual operation switch 1)gas 0)off 2)oilCFM- Manual operation switchCP1-2- Auxiliary contacts pump motorCR1CR9-Auxiliary relay contactsCS- Fan motor contactor - starCT- Fan motor contactor - triangleF- FuseIGB- Main switch with door-interblockIL- Burner auxiliary switchIP1IP5- Magneto-thermic switch for electrical protectionIRA- Auxiliary trim heater switch (for oil filter and pump)LB- Indicating light for burner lockoutLDU11- LANDIS valve leakage monitor deviceLFG- Indicating light for gas burner modeLFL1.xx- LANDIS flame monitor deviceLFN- Indicating light for oil burner modeLL- Indicating light for presence of tension on the electric boxLPN1- Indicator light for oil pump1 functioningLPN2- Indicator light for oil pump2 functioningLPV1- Indicator light for fan motor onLPV2- Indicator light for fan motor offLRA- Auxiliary trim heater indicator lightLRP- Oil trim heater indicator lightLS- Indicating light for burner STAND-BYLSBG- Indicating light for gas low pressureLSPG- Indicating light for leakage of gas valvesLT- Indicating light for motor thermal lockoutLTA- Indicator light for ignition transformer functioningLTOMAX- Indicating light for high oil temperature (signal from TO max)LTP1- Indicator light for oil pump 1 thermal lockoutLTP2- Indicator light for oil pump 2 thermal lockoutPR- Reset button for RVW20PS1- Lockout reset button LFL..PS2- Lockout reset button LDU11PV1- Fan motor on buttonPV2- Fan motor off buttonR1R9- Auxiliary relaysSPN- Oil pump selector 1)pump1 0)off 2)pump2

10

4 REFRACTORY TILEIt is necessary that the tile be installed properly. There must be adequate room for expansion and the tile must not bear the wei-ght of the boiler front wall refractory. It is also important that the tile doesnt extend into the furnace area past the inner face ofthe boiler front refractory over 50 mm. Installation drawing below provides instructions for installing the tile segments. Importantpoints to be considered during installation are:!!!! before the tile is installed, it is necessary to be sure no boiler frontwall refractory weight will be supported by the tile. It is advi-

sable to install a refractory arch of either arch or circle brick or plastic refractory to an inside finished diameter noted on theinstallation drawing as Furnace opening I.D.. This provides a good solid background for the tile and removes the boiler fron-twall refractory weight from the tile.

!!!! the space between the burner tile and the refractory throat should be filled with a plastic refractory or castable on the bottomhalf of the throat to pick up the weight of the tile and should be filled with high temperature insulation on the top half to allowfor tile and frontwall refractory expansion. A good bonding mortar of high temperature and low shrink should be used to bondthe tile together.

Fig. 4

Key1 Firebrick ring not by CIB Unigas2 Fill bottom half of space with castable or plastic refractory3 Fill top half of space with high temperature insulation

Rough dimensions of burner tile in mm

Tile Size 12 14 16 18 20 22 24 26 28 30 32 34 36A 305 356 406 457 508 559 610 660 711 762 813 864 914B 660 711 762 813 864 914 965 1016 1067 1118 1168 1219 1270C 711 762 813 864 914 965 1016 1067 1118 1168 1219 1270 1321

11

5 PILOT BURNERThe burner is equipped with an electrically ignited gas pilot which can be operated with either natural or liquid petroleum gas.It is composed by a net diffuser, an electrode for ignition, an isolator, one or two electromagnetic valves and a pressure gover-nor.

Pilots utilise also a raw gas tube that induces raw fuel into the pilot flame that greatly increases its size for ease of main f lameignition.The pilot provides sufficient flame to instantly, reliably ignite the main burner fuel, providing that pressure has to be regulated inorder to have a good flame; it means that:!!!! pressure has not to drop too much for not loosing the flame!!!! pressure has not to increase too much for avoiding flame breaking.

PILOT GAS TRAIN

1 5 3 4 6 6 27

Key1 Manually operated valve (3/4)2 Pilot burner 3 Pressure gauge with manual cock (600 mbar)4 Pressure switch(Dungs GW50)5 Gas governor with filter(FRG/2MT with spring 140-320)6 Safety gas valve for pilot (EG12L - EG12 SR)7 3993706Flexible hose (flex 1/2)

Fig. 5

5.1 ADJUSTMENTS

Fig. 6

Fig. 7

5.2 ADJUSTMENT OF GAS PRESSURE GOVERNORAlways follow manufacturer instructions for detailed proce-dures. Each regulator must be fitted with the right spring forit to function properly. Further, the spring position must beadjusted to obtain the exact pressure required at the inlet ofgas valves and other controls.

ADJUSTING WHEEL

5.3 ADJUSTMENT OF GAS PRESSURE SWITCHAlways follow manufacturer instructions for detailedprocedures.Pressure switches are electric devices opening or clo-sing safety contacts when gas pressure is too high ortoo low.The initial value should be set to 80 mbar.

12

6 MAIN GAS TRAIN

1

Key1 Manually operated valve (2)2 Main Gas Burner3 Pressure gauge with manual cock (1 mbar)4 Pressure switch (Dungs GW500)5 Gas safety valve (MVD520/5 / VGG10504 + SKP20, red spring AGA23)6 Pressure switch for tightness control (Dungs GW150)7 Butterfly valve with servomotor (P510+SQM54)8 Gas governor with filter (FRG/2MC 2 + spring 180-450)9 Belllows unit (Giuliani Anello 2)The gas flow is controlled by means of pressure downstream of the regulator and by means of butterfly position. Properly sizednozzles are installed for getting the right gas flow rate according to furnace and gas train pressure.

3 8 4 5 6 5 7 3 4 9 2

6.1 ADJUSTMENTSFig. 9 - MINIMUM GAS PRESSURE SWITCHAlways follow manufacturer instructions for detailed procedures.Pressure switches are electric devices opening or closing safety contacts when gaspressure is too high or too low. Set the desired pressure by means of the adjustingwheel W; initial value: 200 mbar.For tuning of set point, read pressure at the outlet while burner is at maximum flowrate, then set pressure switch at 50% of the read pressure.Fig. 9 - MAXIMUM GAS PRESSURE SWITCHAlways follow manufacturer instructions for detailed procedures.Pressure switches are electric devices opening or closing safety contacts when gaspressure is too high or too low. Set the desired pressure by means of the adjustingwheel W; initial value: 300 mbar.For tuning of set point, read pressure at the outlet while burner is at maximum flowrate, then set pressure switch at 130% of the read pressure.PRESSURE SWITCH FOR TIGHTNESS CONTROLAlways follow manufacturer instructions for detailed procedures.Pressure switches are electric devices opening or closing safety contacts when gaspressure is too high or too low.Set the desired pressure by means of the adjusting wheel; set the initial value to 200mbar.Fig. 10 - GAS FILTER CLEANINGBe sure that valve upstream of filter is closed and pressure inside filter itself is zero.Take off filter cover after having unscrewed locking bolts.Replace or clean filter pad. Clean filter box, too.Fig. 11 - SAFETY GAS VALVETo increase or decrease the gas pressure, and therefore gas flow, remove the capand use a screwdriver to adjust the regulator screw VR.Turn clockwise to increase the flow, anti-clockwise to reduce it.Connect up the gas tubing to the gas pressure nipple TP.Leave the breather SA free.Should the spring that is fitted not permit satisfactory regulation, ask one of our ser-vice centres for a suitable replacement.

W

TPSA

VR

Fig. 8

Fig. 9

Fig. 10

Fig. 11

W

13

7 OIL PUMPING UNITThe oil pumping unit is sketched below.The pump is identified by:!!!! maximum rate!!!! pressure!!!! rotation speedThe pump delivers more oil then needed by the nozzle for obtaining the firing rate. For reducing the flow rate to the nozzle, thepressure regulating valve of the oil handling unit has to be adjusted. The balance returns to the tank.

2

6

143

1 5

1Key1 Manually operated valve 22 Oil filter GA 51000 23 Oil pump Suntec TA3 C + motor 1.5 kW4 Check valve 25 Pressure gauge 0 6 bar6 Pressure gauge 0 40 bar

From oil ring

Oil line is traced with self regulating wire

7.1 ADJUSTMENTS7.2 ADJUSTMENT OF OIL PRESSURE SAFETY VALVEAlways follow manufacturer instructions for detailed procedures.The safety valve just after the oil outlet (sometimes it is a built-in one) avoids any mechanical breaking to the pump in case ofabnormal pressure increasing along the line. The safety pressure is adjusted by means of the screw 1 in Fig. 13: turningclockwise the pressure increases.

OIL PUMP SUNTEC TATechnical DataSuction max. 0.5 barMax. recommended depression to avoid formation of air bubbles 0.35 barRotation speed 3600 r.p.m.Operational viscosity 4 to 450 cSt

1 Pressure regulator2 Pressure gauge3 Vacuum gauge5 Nozzle7 Suction8 Return

Fig. 12

Fig. 13

7.3 MAINTENANCE7.4 OIL FILTER CLEANINGMake sure that the fluids to be filtered be compatible with thefilter material. Follow the arrow direction carefully.Working maximum pressure and temperature should neverexceeded. Install the filter with the filtering pack flywheel turnedupwards. No special maintenance is required. To prevent filte-ring pack from getting stuck, turn the filter a few times at leastonce a week.For a complete cleaning of the filter, loosen the screws on thecover, raise the cover and clean with light oil or kerosene.

Fig. 14

14

8 OIL HEATING UNIT

5

9

4

3

10 11

6 8 7 6

6

2

1

Water Discharge

Steam InletP= 8.8 bar

Air SupplyP= 4.5 bar

1 Electric heater 18 kW2 Air governor with filter (Conflow FR10)3 Thermoregulator (Conflow 83R15)4 Temperature switches TCN+TR+TRS5 Heat exchanger (Varisco N.V. 168-1152 + suction breaker valve 1/2 RPVC015)6 Manually operated valve DN157 Steam strainer DN158 Steam modulating valve (Conflow 1000 AR DN15)9 Temperature probe 50 - 150C10 Water discharger (Conflow SSG25 1512 1/2)11 Flow indicator (Conflow IF150/2 1/2)12 Electric heater

Fig. 15

15

8.1 ADJUSTMENTS8.2 ADJUSTMENT OF OIL TEMPERATURE REGULATORSet manually the index in fig. 14, to fix the temperature. Initial value must be set to 120C.See also the addendum for details.

1

2

3

4 5 6

Key1 Setting knob2 Set temperature3 Actual temperature4 Air input pressure5 Air output pressure6 Graduated scale

8.3 ADJUSTMENT OF OIL TEMPERATURE SWITCHESRemove the cover C and set the thermostats as follows:TR 120 CTRS 190 CTCN 80 C

Fig. 16

Fig. 17

8.4 MAINTENANCE8.5 STEAM FILTER CLEANING!!!! Be sure the pipeline is not under pressure; untight

the screws B;!!!! remove the cap C and slip off the filtering element F

for an accurate cleaning.Before refitting the cap be sure the gasket is not dama-ged and replace it if necessary. C

F

B

BFig. 18

C

16

9 OIL HANDLING UNITThe oil handling unit is sketched below.

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17

9.1 ADJUSTMENTS

9.2 OIL PRESSURE SETTINGAdjust the oil pressure by means of the screw S, placed under thecap C. Turn clockwise to increase the pressure or counterclockwiseto decrease it.

9.3 OIL PRESSURE SWITCH SETTING (PO min.)Adjust the pressure range by means of the knob A, reading thescale B. Set the initial pressure to 1 bar.

9.4 OIL THERMOSTAT SETTINGSet the initial value in the oil thermostat TCI, to 90 C

Fig. 20

Fig. 21

Fig. 22

TCI

Fig. 23

9.5 STEAM PRESSURE SETTINGTo set the steam pressure regulator:turn the screw S to adjust the differential pressure, turning clockwiseto increase and anticlockwise to decrease.KeyS Adjusting screwOUT Steam outletIN Steam inlet

IN OUT

S

A

B

A

S

10 MAINTENANCE10.1 STEAM FILTER CLEANINGPlease refer to page 15

18

LOCKING SCREW

REFRACTORY CONE BEGINNING

REFRACTORY CONE END

11 DIFFUSER POSITIONThe position of the diffuser inside the refractory tile can be adjusted while the burner is running. The locking screws have to beunscrewed and the whole lance moved back or forward.The initial position is at the beginning of the cone of the refractory tile. If the fuel wets the tile, move the diffuser forward.

12 NOZZLE POSITIONThe position of the oil tip respect to the diffuser can be adjusted while the burner is running unscrewing the bolt highlighted in thesketch and moving the oil-steam manifold back or forward.For getting the best position, set the initial value of A equal to zero. It means that tip holes are aligned with the smallest base ofthe diffuser cone.Then, move the tip ahead looking at the flame colour. The best position is when the flame is the brightest without wetting the dif-fuser itself. Anyway, look always at the flue gas analysis.

LOCKING BOLT

Fig. 24

Fig. 25

19

13 BURNER FAMILIARIZATION AND INSPECTION13.1 PRELIMINARY INSPECTIONThe burner should be visually checked for damage and loose components as these conditions can occur during shipment,through improper handling, by tempering, or through improper care storage at the job site.

Check for:!!!! Obvious damage to housing, air inlet, and components mounted thereon!!!! Tightness of fasteners, tube fittings, plugs, etc!!!! Tightness of electrical connections and terminals.!!!! Tightness of adjustment mechanism such as ball-joint swivel connectors and control arms.!!!! Accumulations of oil, dust, dirt, water, or other foreign matter on, in, or near the burner.13.2 SUGGESTED INSTALLATION INSPECTION CHECKLIST GENERAL!!!! Is burner installed in accordance with applicable installation drawings?!!!! Is the refractory tile completely dry, cured and ready for firing at full boiler input?!!!! Has the proper electrical voltage been connected to the burner control box as shown on the burner material list?!!!! Has the burner wiring been checked for completeness and accuracy?!!!! Have 3-phase motors been properly wired and checked for correct rotation?!!!! Are the boiler mounted limit controls such as low water cutoffs, high limit controls, operating controls, modulating controls,

etc., properly installed and wired?!!!! Are the boiler controls the right type and range for the installation?!!!! Is the boiler water supply, including feed pumps, properly connected and is the boiler filled with water?!!!! Is sufficient load connected to the boiler so that it can be fired continuously at full rating?!!!! If boiler load is not connected, can steam be wasted so that boiler can be fired continuously at full rating without endangering

personnel or equipment?!!!! If the installation is a hot water boiler, have the circulating pumps been completely installed, wired, and tested to assure pro-

per operation so that the burner can be fired continuously at full rating?!!!! For new boiler installations, has the boiler been boiled out in accordance with the boiler manufacturers instructions?!!!! Have the boiler breaching connections to the stack been completed and are they open and unobstructed?!!!! Is draft control equipment required and, if so, installed?!!!! Have adequate provisions for combustion air been installed?!!!! Is all specified auxiliary equipment mounted and wired? This may include outdoor temperature controls, oil flow switches,

space thermostats, water flow switches, motorized combustion air louvers, etc13.3 GAS FIRING!!!! Are all gas train components installed and have they been properly selected, sized and assembled?!!!! Have properly sized vent lines been installed on all gas train components which require venting? This includes such items as

pressure regulators, normally open vent valves, diaphragm valves, low and high gas pressure switches, etc!!!! Have gas train piping and components been tested and proven gas tight?!!!! Have the gas line been purged?Is the proper gas pressure available at the inlet to the controls which meets the requirement shown on the burner material list?13.4 OIL FIRING!!!! Is the oil tank installed and filled with the proper type and grade of fuel oil as required by the burner material list?!!!! Is the proper oil pressure, temperature and viscosity available at the inlet to the controls which meets the requirements

shown on the burner material list and/or oil system sheet?!!!! Have oil supply and return lines been properly sized to meet the maximum pumping capacity of the pump and has the system

been purged and proven leak proof?

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14 OPERATING SEQUENCE14.1 GAS MODE!!!! The draught fan motor start after a call for heating by the operating control and the pre purge cycle starts.!!!! If the minimum gas pressure switch and the air pressure switch are in the closed position, the cycle continues.!!!! The air louver is in the closed (low fire) position.!!!! At the end of the pre-purge, the gas pilot ignition transformer is energised, the pilot gas solenoid valves open.!!!! Main gas valves open; the burner ignites at low fire rate.!!!! The flame detector proves the flame.!!!! The gas pilot solenoid valves are shut off and the burner runs only with the main gas train.!!!! After this, the modulating motor is driven by the power controller according to the heat release request in order to match the

boiler load.!!!! Gas butterfly valve and air louver are driven according to the set curves of the controller or according to the mechanical devi-

ces linking the two components.14.2 OIL MODE!!!! The draught fan motor start after a call for heating by the operating control.!!!! The oil is circulated by the pump as soon as the oil temperature switch (TCN) is turned on.!!!! Then the pre purge cycle starts.!!!! The oil is vented to the return line passing through the metering valve.!!!! When the oil temperature reaches the set point (TCI), the cycle continues providing the minimum oil pressure switch and the

air pressure switch are in the closed position.!!!! The air louver is in the closed (low fire) position!!!! At the end of the pre-purge, the gas pilot ignition transformer is energised, the pilot gas solenoid valves open.!!!! Main oil and steam (or air) valves open, oil return line is closed and the burner ignites at low fire rate.!!!! The flame detector proves the flame.!!!! The gas pilot solenoid valves are shut off and the burner runs with oil only.!!!! After this, the modulating motor is driven by the power controller according to the heat release request in order to match the

boiler load.!!!! Oil metering valve and air louver are driven according to the set curves of the controller or according to the mechanical

devces linking the two components

14.3 FIRING CHANGE FROM LANCE n 1 TO LANCE n 2If, while oil firing, it is requested to change the operating lance from lance n 1 to lance n 2, follow these instructions.!!!! set the burner output to the minimum firing position operating on the appropriate selector of the remote control panel.!!!! Check lance n 2. It must be in the same position of the firing lance (n 1) respect to the diffuser cone!!!! Lance n 2: connect the flexible hoses either of the oil and of the air/steam.!!!! Lance n 2: open the air/steam valve.!!!! Lance n 2: open the manual globe oil valve !!!! Move the knob acting on item #7.1 of the oil handling unit following the arrows. Put the knob at its end position (it means full

opening of lance 2 and closing position for lance 1). When lance n 1 is operating, label "1" is visible, while, when lance n 2is operating, label "2" is visible.

!!!! Lance 1: close the manual globe oil valve and, later on, close the air/steam valve.

If the oil lance should be removed while the burner is in operation, close the lance seat by means of a steel plate.

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15 TROUBLESHOOTING GUIDEGAS BURNERS

THE BURNER DOESN'T LIGHT No electric power supply Wait for electric power supply is back Main switch open Close the switch Thermostats open Check set points and thermostat connections Bad thermostat set point or broken thermostat Set or replace the thermostat No gas pressure Restore gas pressure Safety devices (manually operated safety thermostat or pressure Restore safety devices; wait that boiler reaches its temperature Broken fuses Replace fuses. Check Ampere absorption Fan thermal contacts open (only three phases) Reset contacts and check ampere absorption Burner control locked out Reset and check its functionality Burner control damaged Replace burner control

GAS LEAKAGE: BURNER LOCKS OUT (NO FLAME) Gas flow too low Increase the gas flow

Check gas filter cleanness Check butterfly valve opening when burner is starting (only Hi-Low

Ignition electrodes discharge to ground because dirty or broken Clean or replace electrodes Bad electrodes setting Check electrodes position referring to instruction manual Electrical ignition cables damaged Replace cables Bad position of cables in the ignition transformer or into the Improve the installation Ignition transformer damaged Replace the transformer

BURNER LOCKS OUT WITH FLAME PRESENCE Flame detector damaged Bad flame detector set Replace or adjust flame detector Bad cables of flame detector Check cables Burner control damaged Replace burner control Phase and neutral inverted Adjust connections Ground missing or damaged Check ground continuity Voltage on neutral Take off tension on neutral (if necessary install the circuit RC466 Too small flame (due to not much gas) Adjust gas flow

Check gas filter cleanness Too much combustion air Adjust air flow rate

BURNER CONTINUES TO PERFORM THE PRE-PURGE Burner control damaged Replace burner control Air servomotor damaged Replace servomotor

BURNER CONTINUES TO PERFORM ALL ITS FEATURES WITHOUT IGNITING THE BURNER Air pressure switch damaged or bad links Check air pressure switch functions and links Burner control damaged Replace burner control

BURNER LOCKS OUT WITHOUT ANY GAS FLOW Gas valves don't open Check tension on valves; if necessary replace valve or the burner

Check if the gas pressure is so high that the valve cannot open Gas valves completely closed Open valves Pressure governor too closed Adjust the pressure governor Butterfly valve too closed Open the butterfly valve Maximum pressure switch (if installed ) open. Check connection and functionality Air pressure switch doesn't close the NO contact Check connections

Check pressure switch functionalityBURNER LOCKS OUT AND THE BURNER CONTROL WINDOW SHOWS A P (LANDIS & STAEFA ONLY)

Air pressure switch damaged (it keeps the stand-by position) or Check air pressure switch functionality Reset air pressure switch

Air pressure switch connections wrong Check connections Air fan damaged Replace motor No power supply Reset power supply Air damper too closed Adjust air damper position

BURNER LOCKS OUT WHILE NORMAL RUNNING Flame detector circuit interrupted Check wiring

Check photocell Burner control damaged Replace burner control Maximum gas pressure switch damaged or badly set Reset pressure switch or replace itWHEN STARTING, THE BURNER OPENS FOR A WHILE VALVES AND THEN REPEATS FROM THE BEGINNING THE CYCLE

Gas pressure switch badly set Reset the pressure switch Gas filter dirty Clean gas filter Gas governor too low or damaged Reset or replace the governor

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BURNER STANDS WHILE RUNNING WITHOUT ANY SWITCHING OF THERMOSTATS Thermal contacts of fan motor open Reset contacts and check values

Check current absorptionFAN MOTOR DOESN'T START

Internal motor wiring broken Replace wiring or complete motor Fan motor starter broken Replace starter Fuses broken (three phases only) Replace fuses and check ampere absorption

BURNERS DOESN'T DO HIGH FLAME Thermostat hi-low flame badly set or damaged Reset or replace thermostat Servomotor cam badly set Reset servomotor cam

SOMETIMES THE SERVOMOTOR RUNS IN THE WRONG WAY Servomotor capacitor damaged Replace capacitor

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OIL BURNERSBURNER DOESN'T LIGHT

No electric power supply Wait for electric power supply is backMain switch open Close the switchThermostats open Check set points and thermostat connectionsBad thermostat set point or broken thermostat Set or replace the thermostatNo gas pressure Restore gas pressureSafety devices (manually operated safety thermostat or pressure switch and so on...) open

Restore safety devices; wait that boiler reaches its temperature then check safety device functionality

Broken fuses Replace fuses. Check current absorptionFan thermal contacts open (only three-phases) Reset contacts and check current absorptionBurner control locked out Reset and check its functionalityBurner control damaged Replace burner control

BURNER LOCKS-OUT WITH FLAME PRESENCEFlame detector dirty or damaged Clean or replace flame detectorBurner control damaged Replace burner controlSmoking flame Reset combustion air flow rateCheck the nozzle an, if necessary, replace itCheck cleaness of combustion headCheck chimney suctionCheck boiler cleanessCombustion head dirty Clean combustion head

BURNER LOCKS OUT WITHOUT ANY FUEL FLOW RATENo fuel Fill the tankPump joint broken Check pump pressurePump damaged Check pump suctionReplace pumpCompressed air (or steam) too high Released compressed air (or steam) pressureOil metering valve not open far enough Check air pressureCheck servomotor positionOil valve not energized Check wiring path or replace valveFan motor not efficient Adjust or replace the motorFun or pump motor runs in the wrong way Change rotationObstructed nozzle Clean or replace the nozzlecheck valve in the tank locked or leaking Clean or replace the valveOil filter dirtyPump filter dirty Clean filterSolenoid valve dirty or broken Clean or replace solenoid valve

BURNER LOCKS-OUT WITH FUEL FLOW RATE (NO FLAME)Oil pressure too low Reset oil pressureNozzle dirty or damaged Clean or replace the nozzleWater in the tank Take off all the water from the tankClean all filtersSuction too high Check suction before pump. If necessary clean filters.Ignition electrodes grounded because dirty or damaged Clean or replace electrodesIgnition electrodes badly set Check electrodes position referring to instruction manualCables damaged Replace cablesBad position of cables in the ignition transformer or into the eletrodes Improve the installation

Ignition transformer damaged Replace the transformerPUMP TOO NOISY

Suction too high (over 3.5 bar) (dirty filters, check valve in the tank locked and so on...) Clean filtersReplace check valve in the tankFlexible hoses damaged Replace flexible hosesAir infiltration in the pipes Take off all infiltrationPipe too long or too narrow Increase line size

BURNER RUMBLES WHEN MODULATING TO HIGH FIREBurner is too lean Adjust air-oil ratioDrawer assembly not set properly Check drawer positionOil may be too hot Check oil temperatureFlame is blowing off head Check head position

CARBON BUILD-UP ON THE FIRESIDES OF THE BOILEROil flame not retaining the headDirty nozzle Clean the nozzleOil too cold Check the oil temperatureOil spray impinging on burner head Check position of the nozzle respect to the headSpray angle of the nozzle too wide Reduce spray angle

FLAME IRREGULAR OR SPARKING

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Oil pressure at nozzle too low Reset oil pressureAir flow rate too high Adjust air flow rateOil is too cold Adjust oil themperatureDirt in the oil Check filtersWater in the fuel Take off the waterOil impingement on the combustion head Drawer assembly far too rearNozzle is not protruding through centerhole of air diffuserOil flame not retaining to the headNozzle dirty or damaged Clean the nozzle or, if necessary, replace it

BURNER LIGHTS BUT FLAME DOESN'T RETAIN TO BURNER HEADDrawer assembly not positioned correctly Move forward or bakwardNozzle too far forward through centerhole of diffuser Move nozzle backward respect to diffuserOil or air pressure at nozzle is too low Increase oil or air pressureAir louver too open Reduce air louver openingToo much spread between oil and air (or steam) pressure Set the spread to a proper valueOil temperature too high or too low Set the temperature to a proper value

FLAME IRREGULAR OR SMOKINGNot enough combustion air Adjust air flow rateNozzle dirty or damaged Clean or, if necessary, replace itFlame is too big for furnace or nozzle spray angleis wrong Check burner-furnace couplingChange nozzle with a suitable oneNozzle spray angle wrong (flame too long or too wide) Replace the nozzleBoiler dirty Clean the boilerNot enough suction at chimney Check chimney cleaness or sizePressure at nozzle too low Reset oil pressureOil too cold Reset oil temperatureCombustion air inlet dirty Clean the air inletFlame is too small respect to furnace volume Replace nozzle or reset pump pressure

FUEL GAS TEMPERATURE TOO HIGHBoiler dirty Clean the boilerOil flow rate too high Adjust oil pressure or replace the nozzle

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16 SPARE PART LIST Project 00P270 - URB4

DESCRIPTION CODEBurner Control LFL 1.333 2020448Electronic cam RVW 20 2570101Regulator Gefran 1600 V RRR0-I0-1801 -Pressure probe QBE 620 - 40 bar 2560162Tightness control LDU11 2020413Flame control QRA10C 2510013Servomotor Landis SQM54.480A2 2480051Potentiometer Landis ASZ 12.803 2560139Electric transformer Cofi 820 2170108Refractory tile (1 piece) 2994116Gas valve Landis VGG 10.504 2190150Gas governor Landis SKP20 2190120Gas valve Dungs MVD 520/5 21903F9Gas valve Brahma EG12L 2190510Gas valve Brahma EG12SR 2190502Gas governor Madas FRG/2MT "-Gas governor Madas FRG/2MC 2 "2800067Gas pressure switch Dungs GW 150 2160026Gas pressure switch Dungs GW 500 2160034Oil pump Suntec TA3C 2590119Oil filter Giuliani Anello 51000/0.5 2" 2090209Oil nozzle tip AB100 -Mixing plug AB100 -Oil valve Joucomatic N.C. E290A384 "2190704Oil valve Joucomatic N.O. E290A387 "2190705Oil pressure switch Danfoss RT 1 2160081Oil governor Carraro UBAN AS1/130 "2570066Oil metering valve Hauck S3-11 2570017Oil metering valve Hauck S3-13 2570018Oil temperature regulator Conflow 83R15 2570067Camozzi air valve N.C. 1/8" 2190734Steam valve Conflow 1100AR DN15 N.C. 2191310Steam check valve Conflow RPX DN15 2191416Steam strainer Conflow FY16 DN15 2090308Steam manual valve DN 15 2810032Water discharger Conflow SSG25 1512 "2191309Flow indicator Conflow IF150/2 2191307Air governor Conflow FR10 2800125Steam modulating valve Conflow 1000 AR DN15 2191304Differential steam valve Carraro UBAN V/D2/AF2/130 DN15 2192405