RPD 20 GL - GS-R GB (20050614)
RPD 20 GL - GS-R GB (20050614)
RPD 20 GL - GS-R GB (20050614)
04/2005 102.884.3016
Inhalt
2
General Information
3
Technical
Technical Data
Data Sheet
Sheet
Duoblock Dual Fuel Burner
RPD 20 GL-R / GS - R
Feld52:
RPD 20 GL-R / GS-R
Output range
kW
3500
3300
3000
2500
2000
1500
1000
500
500
0
RPD 20
4
RPD 20 GL-R / GS - R
Description
Dimensions
Operating mode dary stream. The flame shape may be Monitoring system
Fully automatic forced draught dual fuel adapted by adjustable twist dampers. Flame monitoring by means of flame
burner, safety equipment according to sensor and tested burner control box.
EN 267 and EN 676, especially desi- Control systems Combustion air monitoring achieved
gned for high turn down ratios. oil side: adjustable by means of return through differential air pressure switch,
flow system with compound controller resp. speed control switch in case of
Electric design and spill back nozzle. burner with speed control regulation.
Burner pre-wired and ready to con- gas side : fuel throughput controlled by
nect. All burner components wired to compound controller with adjustable Ignition
the burner terminal rail. Burner control cam disc and gas inlet butterfly valve. Direct electric high voltage ignition,
box supplied loose for installation in air side : by means of compound con- 5000 V, by means of an inbuilt ignition
separate control panel. Separate fitted troller with adjustable cam discs for pri- burner.
oil pump assembly. mary air (air dampers) and secondary
air (air cylinder).
Combustion air
Separate combustion air blower with
stable and pulsation-free characteristics
also on appliances with a high flue gas
resistance. The combustion air volume
is divided into a primary and a secon-
set screw M
length K
RPD A1 B1 B2 B3 B4 B5 B6 B8 D1 D2 D3 D4 D5 D6 D7 G H1 H2 H3 H4 K L1 L4
R 530 53,5 29 90 314 91 560 325 530 500 270 260 210 - 12 250 385 265 650 425 30 465 68
RPD L5 L6 M P1 P2 P3 P4 R T T1 T2 T3 U V W X Y Z LB C FI F2 F3
R 780 - 10 430 510 236 316 - 112 150 240 - 1/2" 2" 140 2x143 4x120 10 - - - - -
5
Burner Construction
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
6
Mounting the Burner to the Boiler
Boiler lining
The boiler lining must consist of heat-
Burner
resistant materials (temperature resi-
stance >1400°C).
7
Combustion Air Fan
Drive Modes
3. V-belt drive
The fan impeller is mounted on its own
shaft by means of a bearing specifically
designed for the purpose. The power is
transmitted from the drive motor via V-
belts which can provide practically any
desired speed.
8
Dimensioned Drawing for RPD Burner 20 - 100
Set screw M
Lenght K
Boilerplate holes
9
10
*) Note: If longer flame tubes are used, the extended lenght must be
Dimensions of RPD Burner 20 - 100 added to the dimensiones G, R, L5
Oil, Gas and Dual-fuel burners **) 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
(without external exhaust gas return)
RPD A1 B1 B2 B3 B4 B5 B6 B8 D1 D2 D3 D4 D5 D6 D7 G H1 H2 H3 H4 K L1 L4 L5
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 2x143 4x120 10
30 62 12 580 670 320 410 1265 140 497 160 192 491 346 22x1,5 80 248 4x92 5x126 10
40 50 12 580 670 320 410 1265 140 497 160 192 491 346 22x1,5 80 248 4x92 5x126 10
50 55 12 740 830 416 506 1743 115 595 181 250 530 376 22x1,5 125 319 3x152 5x156 10
60 62 12 750 840 470 560 1760 195 622 181 270 555 401 22x1,5 125 379 4x129 5x160 10
70 85 12 936 1026 600 690 2010 270 705 181 365 610 450 28x1,5 125 410 5x128 7x140 10
80 92 12 1102 1192 700 790 2320 310 800 187 310 707 495 28x1,5 200 489 6x125 9x128 10
90 - 12 1300 1390 742 832 2720 240 845 224 310 832 620 28x1,5 200 494 6x132 10x135 10
100 - 12 1300 1390 742 832 2720 240 845 224 310 832 620 28x1,5 200 494 6x132 10x135 10
Burner scheme
Gas train
TRD 604 - 72 hr :
Burner scheme TRD 604 - 72 h
gas The 310, 311,312, 313, 313a pressure swit-
ches are approved in dual mode or under the
code of "special construction requirements",
the solenoid valve RL (182) in the return line
oil feed line is required.
TRD 604 - 24 hr :
The 310, 311, 312, 313, 313a pressure swit-
oil return line ches are designed in single mode. The sole-
noid valve RL (182) is built in if the return
flow pressure / ring line pressure exeeds 1
bar.
ignition gas
ignition electrodes EN :
The 310, 311, 312, 313 pressure switches
primary air are designed in single mode.
secondary air
The 313a max. pressure switch is not availa-
air
ble. The solenoid valve RL (182) is required.
100 Burner
Burner scheme fuel oil EL und S (TRD 204-72h) 120 Secondary air cylinder
Tubing with VK-Controller 125 Primary air damper
gas 141 Ball valve
142 Gas filter
143 Pressure gauge with manual valve
oil feed line 144 Pressure governor
145 Safety shutt-off valve
147 Test burner w. push button valve
148 Safety blow off valve
150 Gas butterfly valve
oil return line 151 Ignition burner lance
152 Air regulating valve
ignition gas
153 Main gas solenoid valve
ignition electrodes 154 Safety shutt-off solenoid valve
155 Ignition gas solenoid valve
primary air 156 Ignition gas solenoid valve
air 157 Gas regulating valve
secondary air
167 Ball valve (only heavy-oil)
177 Pressure gauge with manual valve
178 Oil solenoid valve, feed line(115 V)
180 Nozzle assembly with shut-off valve
181 Solenoid valve, oil circulation (only
heavy-oil)
182 Solenoid valve, return line (115 V)
183 Oil hoses
Gas train TRD 604 - 72 h 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
primary
313 Gas pressure switch, low
313a Gas pressure switch, high
air 314 Gas leakage control
349 Mechanical compound controller
secondary
11
Operation
Complete hydraulic valves and The volume flow control valve installed Basic module
instruments group in the return pipe consists of a bush
pressed into the hydraulic valves and
3
instruments group and locked against
torsion and a control shaft. As the con-
1 trol shaft is turned, the contoured confi-
2 guration of the bush and shaft will
change the open cross section for the
oil flowing back and thus vary the oil
return flow rate. Control shafts with dif-
ferent control contour parameters are
available for adjustment to various oil
nozzle sizes. This concept ensures that
an excellent control characteristic and a
wide control range can be covered for a
The hydraulic valves and instruments great variety of applications. The control
group is an integrated concept that contour parameter is affixed to the con- Extension module
combines several functions of the trol shaft by means of an electric mar-
hydraulic systems of burners. Its modu- ker. The current position of the control
lar construction makes it possible to shaft is indicated by the position display.
meet a wide range of requirements and From the "min." mark (low load of bur-
conditions of installation. ner) the control shaft will turn clockwise
Depending on the level of equipment of to the "max." mark (full load of burner).
the hydraulic system, oil pressure swit- If the control shaft has been removed
ches and pressure gauges (3) may be during maintenance work care should
installed in the supply and return pipes be taken when reinstalling it to ensure
of the basic module (1). The solenoid the right mounting position of the control
valve in the supply pipe is of servo-assi- contour by observing the centre punch
sted type while the return valve is mark on the shaft end face. In the low
directly controlled. The solenoids of the load position (min.) the centre punch
two valves are electrically connected in mark will in any case point up (12
series which will prevent one of the val- o’clock position - see figure).
ves being opened alone if any of the If the hydraulic valves and instruments Control shaft installation
solenoids is defective. For the replace- group is used in conjunction with nozzle
ment of the solenoid valves during rods not approved as safety shut-off
maintenance work it should be ensured valve according to EN 264, an exten-
that the right valve type is installed in sion module (2) is available which
the correct direction of mounting. For incorporates an additional solenoid
mounting the solenoid valve in the sup- valve each in the supply and return
ply pipe (type 321 H 2520) it must be pipes. The extension module is atta-
ensured that the direction of flow shown ched directly to the basic module. The
be a stamped arrow on the valve flange modules are sealed against each other
is the same as the direction of flow of by O-rings.
the oil (from the pump to the nozzle Metal hoses are used for connection
rod). The solenoid valve in the return between the hydraulic valves and
pipe (type 121 G 2520) is marked with a instruments group and the nozzle rod.
stamped arrow opposite to the direction The hose lines must be protected
of the oil flow from the nozzle rod back against exterior mechanical damage.
to the pump. The hoses must be positioned and
mounted in accordance with the appli-
cable technical standards. For the
installation care must be taken not to
introduce torsional or buckling stresses
neither by the mounting procedure nor
by movements at a later stage. Speci-
fied bending radii of the hoses must not
be changed.
12
Mounting Position
Leak Test
Ignition Gas Connection
Ignition Burner Type ZT0
13
Ignition Burner Type ZT0
Technical Data
Transformer unit
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.
Construction according to sectional The ionization electrode and ignition When installing new electrodes these
drawing electrode are extended with connecting must be bent, cut to length and adjusted
The igniter consists mainly of the trans- rods (Item 8). These rods are installed as required.
former unit (Item 1) housing the ignition through the bottom of the transformer The internal resistance of the ionization
transformer, the igniter tube with air and housing in 2 ceramic insulators and car- system amounts to some megohms.
mounting flange (Item 6), a gas tube (9) ried by intermediate supporting rings Such a high resistance ensures a good
with nozzle (11) and the electrode car- (Item 7) spaced at 300 mm. insulating capacity of the electrodes and
rier ring (10). The igniter tube with the connecting rods. In a dust-laden com-
Rp1 air connection is bolted to the Flame monitor bustion air environment it is therefore
transformer unit. After the 4 bolts (Item An ionization electrode is provided for important to clean the insulators at shor-
4) have been unscrewed it may be flame monitoring. The flame signal is ter intervals. Humidity should be kept
removed or turned by 90° if required by generated by d.c. current which due to out. See also electrical function.
the position of the air connection. When the ionization effect and the rectifier The ceramic insulator of the ionization
turning the tubes care must be taken effect of the flame is caused to flow from electrode must not be allowed to heat
not to change the position of the inner the igniter tube earth via the flame to up above 500 °C because this could
supporting rings and rods because this the ionization electrode and via the con- lead to shutdown on trouble. Therefore,
might lead to operational trouble. necting rod to the amplifier in the auto- a minimum air flow rate (10-20 % of the
The gas supply may be connected eit- matic furnace controller. The ionization full-load rate) should be allowed to flow
her to the left-hand or right-hand ope- electrode and ignition electrodes are if this temperature is likely to be rea-
ning. The opening not used is closed adjusted in accordance with the dra- ched by radiation or convection with the
with a screw plug which also carries the wing. furnace chamber in hot condition and
screw-in gas test socket (3). The elec- the burner flame turned off.
trode support ring (Item 10) is mounted
to the end of the gas tube.
14
Ignition Burner Type ZT0
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
* Quantity depends on pipe length: 3 intermediate rings per metre of tube length.
** Additional data according to type (tube length).
15
Ignition Burner Settings
Electrode Carrier Ring
Front
view
Side view
Top view
Ceramic Z 545 F 11
Electrodes Z 707 F 3
Preset amount of bend and adjustment
Cut ionization electrode to length according to gas type.
16
Ignition Gas Solenoid Valve
Technical data:
Nominal bore: R1/2“
Max. operating
pressure: 500 mbar
Opening time: < 1 sec
Closing time: < 1 sec
Ambient temperature:-15°C to +70°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
Installation
When installing the valve in the pipeline
take care to observe the arrow on the
valve housing and the required moun-
ting 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 installation make a test for
absence of leaks and proper operation.
Not
acceptable
17
Oil Connection
Fuel Oil Supply
18
Oil Connection
Fuel Oil Supply
Oil connection To avoid burner trouble due to entrained Oil pressure pump filling
For the installation of a furnace system air, a gas-air vent must be provided at Prior to initial operation make sure to fill
care should be taken to observe the the uppermost position of the ring pipe the oil pressure pump and oil feed line
applicable rules and regulations. When system. with oil to prevent the pump from dry
installing an oil burner be sure to follow running and getting seized.
the recommendations outlined for oil- The ring pipe pressure must be control-
fired furnace systems (DIN 4787, led in dependence of the fuel oil tempe- Oil filter
DIN 51603 Parts 1&2, TRD 411). DIN rature. It is recommended to install a filter
4736 Parts 1&2 describes the safety As can be seen from the chart below, directly upstream of the pump to sepa-
requirements applicable to the oil sup- the static pressure of the oil at 130°C rate dirt particles contained in the oil or
ply systems of oil burners. DIN 4755 must be minimum 3 bar, for example. any other foreign matter produced
Part „Oil furnaces in heating installati- during installation. When a fuel oil unit is
ons (safety requirements)“ outlines the Oil pressure in dependence of mounted this will be fitted with an oil fil-
safety recommendations for oil furnace operating temperature ter already.
systems of steam boilers.
The installer has the duty to inform 5
Starting the oil pump
himself of the regulations applicable to - Make sure all stop valves are
gas and oil furnace systems. open.
4
- Check the pump for direction of
Fuel oil supply rotation.
The operational reliability of a burner - The safety overflow valve in the
bar
3
Druckbar
system depends greatly on the oil sup- pump is preset at 40 bar and may
Pressure
19
Medium pressure screw pumps
Installation
Commissioning
Maintenance
2.2 3.5
Ensure stress-free fitting of the pump or Switching off the pump: Residual static
base frame. pressure in the pressure pipe must no
exceed that of the permissible supply
2.3 Coupling pressure. If necessary, de-pressurize
Motor and pump shafts must be aligned. the pump through the non-return valve,
Axial play between the Coupling halves as this pressure pressurizes the shaft
approx. 1.5 mm. It should be possible to seal which in turn could damage the
turn the whole unit of pump shaft-Cou- seal. The same applies to parallel ope-
pling-Motor shaft by hand. Installation of ration of several pumps.
the coupling halves: Sliding on (tapping
not permitted) in heated condition (min.
100°C); Press plastic couplings home in
cold condition.
20
Medium pressure screw pumps
Technical specifications
Function
Versions
Technical specifications
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
Function
Screw pumps have three rotating spind-
les, of which the main spindle supplies
the hydraulic power and the auxiliary
1. Main spindle The axial forces acting on the feed
spindles, which run free, have only a
2. Auxiliary spindle screws are balanced (compensated)
rotating function. The two-speed main
3. Enclosed housing by the compensating piston (9) and
and auxiliary spindles create supply
4. Pump housing compensating bores (8).
chambers within the enclosed housing,
5. Safety valve (adjustable)
which move constantly from the suction
6. Main spindle bearing
to the pressure side. Due to this prin-
7. Seal
ciple the screw pumps can also operate
8. Compensating bore
under high pressures, revolutions and
9. Compensating piston
provide strong suction, they are extre-
S Suction chamber
mely quiet and almost pulse-free.
D Pressure chamber
21
Burner Pump Assembly
Electrical Connection
1 Stop valve
Burner pump assembly
2 Pressure/vacuum gauge
3 Ball valve
4 Oil pressure pump
(volumetric)
5 Drip tray
6 Oil filter
7 Ball valve
8 Flange connection
9 Pump bracket
10 Pump-end coupling
11 Motor-end coupling
12 Electric motor
22
Start-up
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23
Return Nozzle Rod MAT
Functional description The return flow rate is controlled according to the required
The oil delivered by the burner pump will enter the feed pipe output using an output pressure control valve.
(9) via the connection block (10). Approved shut-off valves are installed directly upstream of
Then it flows through the feed pipe (9) at the pre-set pressure the inlet to the nozzle rod in the oil feed and oil return lines.
directly to the return nozzle. Part of the oil delivered will be
returned through the return flow pipe (6) via the return flow
hole of the nozzle.
1. Union nut
2. Nozzle plate
3. Intermediate plate
4. Swirl chamber
5. Nozzle rod
6. Return pipe
7. Feed flow
8. Return flow
9. Feed pipe
10. Connection block
24
Start-up
Return nozzle
W 200
[kg/h]
rate [kg/h]
200 W 180
Öldurchsatz
W 160
Oil throughput
W 145
150
W 130
W 115
W 100
100
50
0
20 21 22 23 24 25 26 27 28 29 30
Supply
Vorlaufoil pressure
Öldruck [bar][bar] Example
Required oil throughput
Throughput rates shall apply to closed return rate 238 kg/h
Nozzle size according
Density: 840 kg/m3 to diagram W2-225
Viscosity: 5 mm2/s Supply pressure according
Nozzle type: W2-50° to diagram 28 bar
25
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 27
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5899
26
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 27
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5902
27
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 27
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5913
28
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 27
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5924
29
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 50
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5946
30
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 50
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5957,
145.513.5968
31
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 50
· Oil [kg/h]
m
2 alpha [°]
p return [bar]
Test conditions:
Article-No.: 145.513.5980
32
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 50
· Oil [kg/h]
m
2 alpha [°]
p return [bar]
Test conditions:
Article-No.: 145.513.5979
33
Throughput Rate Charakteristics
Heavy Fuel Oil
Return Nozzle MK 50
· Oil [kg/h]
2 alpha [°]
m
p return [bar]
Test conditions:
Article-No.: 145.513.5991
145.513.6007
34
Dimensions of the Mixing Unit
(standard versions)
RPD 20 GL-R
35
Draw-out and Swing Mechanism
Burner Settings
Draw-out and swing mechanism ved, the air damper in the burner hou-
The duobloc burners type RPD are sing will also be accessible.
equipped with a draw-out and swing
mechanism. This makes it possible to NOTE: Before removing and swinging
pull out and swing away the complete away the central tube take care to
central tube for maintenance access to mount the draw-out and swing mecha-
the mixing head and for adjusting the nism, disconnect the electric plug con-
mixing and ignition units. nectors of the flame detector and
Prior to this, the fastening bolts of the ignition burner, remove the primary air
central tube must be unscrewed. The connection and disconnect the oil hoses
baseplate of the central tube carries the (in oil and dual-fuel burners) with the
ignition burner, flame detector, nozzle quick-action couplings provided for this
rod assembly (only for oil and dual-fuel purpose.
burners) and primary air connection.
After the central tube has been remo-
36
Air Flow Adjustment
Oil Flow and Gas Rate Adjustment
Air adjustment During adjustment care must be exerci- readily. The level of preheating depends
Check that the air swirler setting is in sed to ensure that over the whole of the on the viscosity of the fuel oil and can
accordance with the furnace/ combu- control range the air pressure at the be determined from the viscosity-tem-
stion chamber geometry and re-set if central pipe (primary side) is 1.5 - 2 perature diagram. The atomizing visco-
required. In order to ensure uniform dis- mbar higher than the combustion cham- sity is at 12 to 15 cSt.
tribution, close the air swirler at the air ber pressure.
pipe entry against air inlet. The air curve Gas adjustment
of the compound controller is factory-set Oil adjustment The gas damper is connected to the
so that the air cylinder is closed at mini- For taking into operation, the oil control mechanical compound controller by
mum settings and open at maximum block with flow control valve in the means of a transmission arm.
settings. return line will be preset. The pump The gas cam of the compound control-
The combustion air ratio (secondary air) pressure is set at approx. 28 bar and ler is factory-set so that the gas damper
to the fuel can be obtained over the the pressure upstream of the control is closed in its minimum position and
whole of the output range by turning the valve at approx. 5 to 18 bar. After loose- open in its maximum position.
screws, which is then checked by ning of the lock screws of the socket- The minimum and maximum positions
measuring the exhaust. headed studs and sliding ball, the con- and the intermediate positions of the
Before the compound controller screws trol curve is adjusted over the whole gas damper are also adjusted with the
can be adjusted, the lock nuts on the control range by means of the cam disk, electronic compound controller. The gas
front face and underside of the com- after which setting is then locked with pressure must be corrected by means
pound controller must be loosened. Set- the lock screws. of the gas pressure controller if neces-
ting of the primary air is also carried out sary. The setting must be checked by
via a cam disk and it can be set accura- Heavy fuel oil making a combustion analysis.
tely by adjusting the threaded studs as Heavy fuel oils must generally be hea-
required. With a large control range the ted up. On the one hand, this is perfor-
minimum combustion output is set by med in the fuel oil storage tank to keep
means of the primary air. the oil in a pumpable state because the
temperature must be above the setting
point. Further preheating is required in
the service tank, fluid preheater or elec-
tric preheater to ensure the heavy fuel
oil can be properly atomized and burns
Flame formation
Air swirler
position
POS 1
Air swirler angle 0 - 20° Spindle-
Pressure loss 30 mbar flame
POS 2
Long
Air swirler angle 20 - 40°
flame
Pressure loss 38 mbar
POS 3
Air swirler angle 40 - 55° Average length
flame
Pressure loss 45 mbar
POS 4
Air swirler angle 55 - 70° Short
Pressure loss 55 mbar flame
37
Mechanical Compound Controller
1 Fuel-air compound controller 16 Return flow connection (only NOTE: For heavy oil operation, the oil
mounting bracket heavy oil) control block and oil flow rate controller
2 Secondary air damper control lin- 17 Feed line hose connector are equipped with electric heaters.
kage 18 Solenoid stop valve
3 Primary air control arm 20 Pressure gauge stop valve
4 Primary air control linkage 21 Oil pump pressure gauge
5 Primary air angular control arm 22 Oil feed connection from burner
6 Spring-loaded sliding block for pump
gas control 23 Oil pressure switch in feed line for
7 Hexagon socket head screw with lack-of-oil monitoring
pressed-in sliding ball (locked by 24 Oil return flow connection
means of hexagon socket head 25 Oil pressure switch in return line
screws on end face of cam wheel) for oil overpressure monitoring
8 Spring-loaded sliding block for 26 Limit switch for oil and gas opera-
secondary combustion air tion
9 Cam disk on drive shaft 27 Oil flow rate control linkage
10 Drive shaft 28 Bypass change-over valve (flus-
11 Spring-loaded sliding block for pri- hing valve)
mary air 29 Pump pressure adjuster for built-
12 Spring-loaded sliding block for oil in primary pressure controller
flow rate control 30 Bypass solenoid valve (flushing
13 Transmission rod for gas flow rate valve)
control damper 31 Return pressure gauge (only
14 Actuator with disconnecting unit heavy oil)
for manual operation
15 Hand wheel for manual adjust-
ment of mechanical compound
controller
38
Pressure Setting
39
Oil Pressure Switch
Air Pressure Switch
Switching difference
The switching difference may be selec-
Setting Switching
Type Location ted on the pressure switches within the
range difference
limits shown in the table. For the adjust-
DSB 143 F... 0 - 6 bar 0,3 - 1,6 bar Return line acc. to DIN / EN ment, turn the threaded pin in the set
screw (3) for the switching point. One
DSB(F) 170 F... 15 - 40 bar 1,2 - 4,5 bar Feed line acc. to DIN/EN in pumps turn will change the switching difference
without quick-action stop valve by approx. 20 % of the total range of the
switching difference. The oil pressure
DSF 146 F... 0 - 10 bar 0,5 - 2,5 bar Return line acc. to TRD 604/ 72h
switch has a facility for attaching a seal.
DSB 158 F... 3 - 25 bar 1,0 - 4,3 bar Feed line acc. to TRD 604/ 72h
40
Setting Pressure Switches and
Control System
41
Automatic Furnace Controller LFL 1... / LGK 16...
LFL 1...-7451 D
LGK 16...-7785 D
Functional diagram
LFL 1... / LGK 16...
42
Flame Monitor
Sensor Current Measurement
Autom. furnace controller LFL 1... Flame monitor with UV sensor UV current measurement with QRA 5
UV sensor with QRA 2... The UV radiation of hot flame gases is For an accurate UV current measure-
utilized for generating the flame signal. ment it is recommended to make use of
The radiation detector used is a UV- the tester KF 8832. If a normal meter
sensitive tube with two electrodes and (microammeter) is used for UV current
being live all the time. This UV tube will measurement it is advisable to make
ignite when subject to light from the the measurement as shown in the
190-270 nm range of the spectrum and figure. For this, a capacitor
thus cause a current to flow to the flame C = 470 µF, 15V (or with higher electric
signal amplifier. strength) must be integrated in the
The UV tube will not respond to the measuring circuit.
after-glowing refractory lining of the fur- Meter: 100 µA/Ri = 3 kΩ
nace, sunlight, daylight or light of the Connect the meter between the auto-
boiler room lighting system. matic furnace controller and the UV
The service life of the UV tube is about flame sensor QRA 5... (terminal 22 (-)
10,000 hours at ambient temperatures and 5 (+)).
Autom. furnace controller LGK 16... up to 50°C; higher ambient tempera- Take care to observe the right pola-
UV Sensor with QRA 5... tures will considerably reduce its ser- rity.
vice life.
Alignment of the UV sensor QRA 5...
Burners operated continuously or inter- The mounting flange is movable sup-
mittently for more than 24 hours without ported on the sensor tube to allow the
interruption (e.g. boiler sequence con- exact alignment of the sensor window
trol) or burners operated on steam boi- relative to the direction of incidence of
lers must be equipped with the the UV radiation.
automatic furnace controller of type
LGK 16... and its associated self-con- NOTE: The terminal (22) must be con-
trolling flame monitoring circuit (QRA nected to earth all the time.
5...).
For data and design instructions refer to Cleaning the sensor
automatic furnace controller: Check the UV sensor window for possi-
ble accumulation of dirt at regular inter-
LFL 1... No. 7451 D vals and clean if required. Take care the
LGK 16... No. 7785 D sensor window is free of dust all the
time.
If upon cleaning the sensor does not
properly work it will be required to
replace it by a new one.
Sensor currents
43
Stellantrieb Schimpf
Typ 01-15/30
Typ 02-25/2500
Typ 02-25/3000
Technische Daten:
30 2500 3000
Voltage: 230 V AC 230 V AC 230 V AC
Frequency: 50 HZ 50 Hz 50 Hz
Operating time: 60 sec. bei 90° 60 sec. bei 90° 30 sec. bei 90°
Torque: 12 Nm 20 Nm 31 Nm
Limit switch 4 thereof 2 pot. free 4 thereof 2 pot. free 4 thereof 2 pot. free
Description
The actuator type ARIS-N is designed
as a controlling element for oil/gas or
dual-fuel burners with sliding or modula-
ting control concept. The actuator is
equipped with a short-circuit-proof syn-
chronous a.c. motor which drives a
shaft via a maintenance free spur-gear
unit with permanent grease lubrication.
The shaft end carries a coupling for
operating the controlling element for
fuel and combustion air. The actuator is
designed for two-wire control by control-
lers or switching units with change-over
contact (single-wire control is possible).
A feedback potentiometer is used as a
optional feature.
A conductive plastic potentiometer is
used for position feedback. The actua-
tor is TÜV-approved and permitted for
the application with electronic com-
pound controller.
44
Solenoid Safety Valves
TECHNICAL DATA
Function 2/2 electromagnetic safety shut-off valve and rapid action device actuated in oil-firing
equipment according to DIN 32725 (DIN EN 264). TÜV tested. Used as well in connec-
tion with atomizing oil burners according to DIN 4787 and oil firing systems with steam
boilers according to TRD 411.
Mounting Direct pipe mounting or with two threaded holes at the lower connection area (please
refer to dimensional drawing).
Material specifications Valve body from brass. Internal parts from stainless steel. Bearing plate from ruby and
elastomere from oil resistant viton (FKN).
Media Fuel oil EL, L, M, S (DIN 51603), please refer to the table.
Filter Filters according to DIN 32727 must be connected in series to the 321 H/F valve
Ambient temperature 0 °C to 60 °C
Flow factors kv = 2 to 60 (please refer to the table). The tolerance concerning flow factors is +/- 15 %.
Coil housing Metallic housing covered with epoxy resin, 360° rotating, with Pg11 cable screwing.
System of protection IP 44. Galvanized metallic housing, 360° rotating, with Pg11 cable
screwing. System of protection IP 67.
45
Solenoid safety valves
46
Pipe spring - Glycerine - Manometer
Bimetal - Pointer - Temperature controller
0-6 bar -
0 - 10 bar -
0 - 16 bar -
0 - 25 bar 3333 261 128
0 - 40 bar 109 016 0374
0 - 60 bar 109 811 4290
0 - 100 bar 109 811 4303
47
Flushing and Oil Feed Start
Thermostat ATH 22
48
Gas Connection
For the installation and taking into ope- Gas control group with two gas Gas connection pressure:
ration of the gas lines care should be valves and leak tester: The gas line must be dimensioned in
taken to observe the regulations of The gas section is designed in accor- accordance with the throughput rate
DVGW (German Association of the Gas dance with EN 676 and TRD 412, two and the available gas pressure and
and Water Sector) especially DVGW- gas valves and leakage tester are installed to the burner on the shortest
TRGI (Technical Regulation for Gas prescribed for burners with a capacity possible way with minimum pressure
Installations) and TRF (Technical Regu- above 1200 kW. loss.
lation for Furnaces). The operation, mounting and adjust- To provide the most effective conditions
DIN 4756 and TRD 412 contain specifi- ment of the valve leak testers is descri- for start-up, take care that the burner
cations for the construction, design and bed in detail on a separate sheet. and gas stop valve are installed with the
safety requirements of gas furnaces in minimum possible distance between
heating installations. Furnace systems one another. This means that the 2nd
of higher operating pressures are sub- gas valve (looking in the direction of the
ject to the DVGW Worksheets G 460 gas flow) should be mounted in the
and G 461. The gas lines must meet immediate vicinity of the burner.
specifications set out in DVGW-TRGI in Note the gas pressure loss of the gas
the case of furnace systems with opera- control group and burner. The gas con-
ting pressures up to 100 mbar or above trol group can be connected directly to
100 mbar. the gas feed line. Note the order in
which the valves and instruments are
mounted and the direction of flow. Prior
to installation and taking into operation,
check the valves and instruments and
the connection fittings for the possible
accumulation of dirt and foreign matter.
49
Gas Motor Valve VK
50
Gas Motor Valve VK
VK..Z
51
Gas Pressure Regulator
Instrument line ∅ 12 mm
appr. 10 x d
Blow-off line
Instrument line
12 mm outside ∅
appr. 10 x d
52
Gas Pressure Regulator
with Safety Diaphragm,
Inlet Pressure Compensator, Zero Lock
Setpoint adjustment
The setpoint will be adjusted by selec-
ting the desired range of the setpoint
spring and adjusting the setting spring
accordingly. The layout of ranges is
according to the spring configuration.
Instrument line
It will not be necessary to reposition the
instrument line because the controller is
equipped with an internal pulse sensor
as a standard feature.
Installation
Prior to installation check that the con-
necting lines and regulators are free of
dirt. Dirt-carrying gas may cause
damage to the seat and cone of the
regulator. For the installation take care
to observe the direction of the arrow.
Hold regulators with threaded connec-
tions only by means of suitable tools
engaging the surfaces intended for this
purpose. For the connection of flanged
joints take care to tighten the bolts by 1 Housing bottom 15 Adjusting screw
even amounts all around. 2 Regulator seat 16 Screw cap
3 Regulator sealing 17 Position indicator for
Control and start-up 4 Regulator disk DN 40/DN 150
With the setpoint setting known to be in 5 Bottom spacer sleeve 18 Cover
its correct position: 6 Compensating diaphragm 19 Bottom cover
Proceed with slowly opening the stop 7 Top spacer sleeve 20 R1/4" thread on either side of
valve upstream of the regulator. Then 8 Override tube inlet pressure chamber for
turn on the gas-consuming equipment. 9 Working diaphragm inserting the test socket
Depending on the mounting position it 10 Safety diaphragm 21 Leakage gas connection
might be necessary to slightly readjust 11 Diaphragm disk R 1/4" for DN15/DN25 (R 1/2"/R
the pressure (turning the setpoint set- 12 Setting pressure spring 1") R1/2" for DN 40/DN150
ting screw clockwise or counterclock- 13 Screw 22 Diaphragm cup
wise will increase or decrease the 14 Screw plug 23 Diaphragm plate
pressure, respectively).
With the setpoint setting not known or in
Maintenance
its incorrect position:
The gas pressure regulator is mainte-
Proceed with fully relieving the setpoint
nance free. Dirt-carrying gas may howe-
spring of load (turning counterclock-
ver necessitate an occasional cleaning
wise); open the stop valve slowly and
of the unit. In case of a failure of the
cautiously; set the desired setpoint to
working, safety or compensating dia-
an approximate position with the gas-
phragms due to the impact of excessi-
consuming equipment not turned on
vely high pressure it will be necessary
and proceed with the exact setpoint set-
to order a new measuring element for
ting at nominal load. If the setting range
the particular type (all functional parts of
of the setpoint spring is not sufficient,
the regulator available as a kit).
select the correct spring from the table
of springs.
53
Gas Pressure Regulator
with Integrated Safety Valve
Installation
The gas pressure regulator must be
installed with the arrow pointing in the
direction of the gas flow. Two instrument
lines must be fitted, one to the bottom
diaphragm cup of the regulator part and
one to the upper diaphragm cover of the
safety shut-off valve (approx. 10 D
downstream of the control unit). These
lines should be of steel type with an out-
side diameter of 12 mm. The Ermeto
self-sealing couplings are provided by
the manufacturer.
1 Setting screw 11 Vent opening
Taking into operation
2 Load spring 12 Inlet pressure compensating valv
Open the gas shut-off valve very slowly.
3 Main diaphragm 13 Safety shut-off valve seat
Watch the outlet pressure on the pres-
4 Vent opening R 3/8" 14 Valve sealing
sure gauge and readjust the load spring
5 Instrument connection R 3/8" 15 Closing spring
if required. Take care for adjustment
6 Inlet pressure compensating 16 Safety shut-off valve diaphragm
that the gas is not flowing because
diaphragm 17 Maximum spring
otherwise the closing pressure will be
7 Valve seat 18 Setting screw
added to the measured result.
8 Valve sealing 19 Pull knob
9 Closing cover
Operation
10 Instrument connection R 1/4"
The gas will flow through the regulator
housing in the direction of the arrow.
The main diaphragm will be charged
with pressure to the outlet side from the
bottom via an instrument line. The load
spring is preset to the desired outlet
pressure. The single-seat valve is
directly hung and isolated from the inlet
pressure by an intermediate diaphragm.
The diaphragm of the safety shut-off
valve is charged with outlet pressure via
an instrument line. Overpressure and/or
lack of pressure will cause the measu-
ring element to lift or lower. This will
actuate the tripping mechanism with the
closing spring pressing the valve disk
against the valve seat.
54
Gas Filter
Safety Vent Valve
Filter replacement
The filter cartridge should be replaced
by a new one as soon as a high pres-
sure drop is noticed. If a new filter cart-
ridge is not at hand it will be possible to
wash the filter mat in 40°C water adding
some light-duty detergent. Allow the
mat to dry before reinstallation.
1 Setting screw
2 Load spring
3 Diaphragm
4 Vent opening R „
5 Internal influencing feature
6 Valve sealing
7 Valve seat
8 Closing cover
55
Diagram Pressure Loss
56
Preoperational Checks
Functional Flow
Gas Start-up
57
Start-up Light Oil
Checking Procedure
Function of the steplessly Check the following prior to the Oil start-up
controlling light oil burner initial operation of the boiler system:
- Open all stop valves of the oil supply
The light oil is supplied to the high-pres- - Take care to observe the operating system; fill pumps with oil.
sure pump by an oil pump via ring line, instructions supplied by the boiler - Install feed pressure gauges, vacuum
gas-air separator and service tank. manufacturer. The boiler must be gauges, pumps, etc.
The light oil is flushed via the pressure mounted ready for operation. - If a ring line is provided fill this with oil
control valve on the oil control block. - Ensure that the heating system is filled and take it into operation. Check oil
When closing this flushing valve the oil with water. temperature.
pressure will build up and open the - Check the complete system for correct
hydraulic ball-type valves in the feed electrical wiring. NOTE: The hydraulic system is factory-
and return lines. - Check the air fan and pump motor for filled with test oil which might lead to
The pressure control valve (in oil control correct direction of rotation. ignition trouble during initial start-up. To
block) installed downstream of the high- - For checking the direction of rotation protect the pump the oil pressure con-
pressure pump will keep the oil pres- of the air fan and pump motors (direct troller is factory-set at a low pressure
sure at the constant level of 28-30 bar in connection) shortly actuate or press only. When starting the burner make
accordance with an overflow principle. the contactor. sure to increase the oil pressure to ope-
The nozzle rod assembly has 2 connec- - In star-delta connection layouts it will rating level gradually.
tions, the oil feed and the oil return con- be necessary to actuate the mains and
nections. Two types of nozzle rods can star contactors at the same time. Prior to initial fuel feed start make a
optionally be used, i.e. the RDG/RDN - Check the correct direction of rotation functional test of the burner program
and the MAT nozzle rods. of the oil pump by comparison with the flow.
In the light oil mode it will be possible to direction-of-rotation arrow stamped to
actuate, the feed and return valves at the pump. Disconnect the lifting magnet of the
the same time. - Check for the proper setting of the nozzle needle valve (solenoid valve) by
After the nozzle needle valve has ope- temperature and pressure controllers, reference to the wiring diagram.
ned in the nozzle rod the oil pressure limiters, safety switches and electrical Start the burner and check the program
will be controlled via an oil controller in limit switches. flow for correct sequence of start-up
the return line (minimum pressure - Bleed the fuel carrying lines, pumps operations.
approx. 3-5 bar; maximum pressure and pre-heaters (make sure no air is
approx. 16-18 bar). contained). 1. Flush via oil control block.
If the compound controller is increased - Check that the tank, lines and oil pump 2. Fan.
to maximum output, the oil pressure will are filled with oil and that the proper oil 3. Air damper pre-ventilation (check
be brought to approx. 16-18 bar (maxi- nozzle has been fitted. limit switch setting).
mum output of nozzle). This output - Make a test of the hydraulic oil system 4. Check air pressure.
must correspond to the rated output of for absence of leaks. 5. Air damper starting load (check
the heat generator as shown in the - Check the exhaust gas ports are ope- limit switch setting).
nozzle output diagram. ned and sufficient fresh air is taken in. 6. Ignition (ignition gas valves).
Simultaneously with the oil flow rate - With the burner in starting position 7. Fuel valves.
control, the air flow rate control cam of check that air damper is closed. 8. Shutdown on trouble after safety
the compound control system will con- - Check that the automatic furnace con- time has run down (see automatic
trol the air flow rate required for the troller is unlocked and in its original furnace controller).
combustion of the oil quantity supplied. position. 9. Unlock automatic furnace control-
ler.
58
Start-up Heavy Oil
Checking Procedure
Function of the steplessly Check the following prior to the Oil start-up
controlling heavy oil burner initial operation of the boiler system:
- Open all stop valves of the oil supply
The pumpable heavy oil is supplied to - Take care to observe the operating system; fill pumps with oil.
the high-pressure pump by an oil pump instructions supplied by the boiler - Install feed pressure gauges, vacuum
via ring line, gas-air separator and ser- manufacturer. The boiler must be gauges, pumps, etc.
vice tank. mounted ready for operation. - If a ring line is provided fill this with oil
The high-pressure pump circulates the - Ensure that the heating system is filled and take it into operation. Check oil
heavy oil through the preheater, pres- with water. temperature (min. 50-60°C depending
sure control valve and flushing valve of - Check the complete system for correct on viscosity).
the oil control block. In this process the electrical wiring.
oil is heated up and brought to atomi- - Check the air fan and pump motor for NOTE: The hydraulic system is factory-
zing viscosity (approx. 12 to 15 cSt). correct direction of rotation. filled with test oil which might lead to
The flushing valve will be closed after - For checking the direction of rotation ignition trouble during initial start-up. To
the preset oil temperature has been of the air fan and pump motors (direct protect the pump the oil pressure con-
reached. connection) shortly actuate or press troller is factory-set at a low pressure
The pressure control valve installed the contactor. only. When starting the burner make
downstream of the high-pressure bur- In star-delta connection layouts it will sure to increase the oil pressure to ope-
ner pump will keep the oil pressure at be necessary to actuate the mains and rating level gradually.
the constant level of 28-30 bar in accor- star contactors at the same time.
dance with an overflow principle. Check the correct direction of rotation Prior to initial fuel feed start make a
The nozzle rod assembly has 2 connec- of the oil pump by comparison with the functional test of the burner program
tions, the oil feed and the oil return con- direction-of-rotation arrow stamped to flow.
nections. Two types of nozzle rods can the pump.
optionally be used, i.e. the DG75 and - Check for the proper setting of the Disconnect the lifting magnet of the
the MAT nozzle rods. temperature and pressure controllers, nozzle needle valve (solenoid valve) by
If the DG75 nozzle rod is used, the sole- limiters, safety switches and electrical reference to the wiring diagram.
noid valves will be opened in the feed limit switches. Start the burner and check the program
and return lines for approx. 45 seconds - Bleed the fuel carrying lines, pumps flow for correct sequence of start-up
prior to fuel feed start. A flushing pro- and pre-heaters (make sure no air is operations.
cess is started via the nozzle rod and contained).
output controller so as to ensure the - Check that the tank, lines and oil pump 1. Flushing (oil temperature).
required fuel oil temperature also imme- are filled with oil and that the proper oil 2. Fan.
diately upstream of the nozzle. nozzle has been fitted. 3. Air damper pre-ventilation (check
A flushing operation is not used with - Make a test of the hydraulic oil system limit switch setting).
burners having the MAT nozzle rod. In for absence of leaks. 4. Check air pressure.
this case the required viscosity is achie- - Check the exhaust gas ports are ope- 5. Air damper starting load (check
ved by heating the nozzle rod. ned and sufficient fresh air is taken in. limit switch setting).
After the solenoid valves or nozzle - With the burner in starting position 6. Ignition (ignition gas valves).
needle have opened, the oil pressure check that air damper is closed. 7. Fuel valves.
will be controlled via an oil controller in - Check that the automatic furnace con- 8. Shutdown on trouble after safety
the return line (minimum pressure troller is unlocked and in its original time has run down (see automatic
approx. 3-5 bar; maximum pressure position. furnace controller).
approx. 16-18 bar). 9. Unlock automatic furnace control-
If the compound controller is increased ler.
to maximum output, the oil pressure will
be brought to approx. 16-18 bar (maxi-
mum output of nozzle). This output
must correspond to the rated output of
the heat generator as shown in the
nozzle output diagram.
Simultaneously with the oil flow rate
control, the air flow rate control cam of
the compound control system will con-
trol the air flow rate required for the
combustion of the oil quantity supplied.
59
Viscosity as a Function of Oil Temperature
Temperature [°F]
M
ax
i m
um
vi
Kinematic viscosity ν [mm²/s = cSt]
Temperature [°C]
60
Oil Start-up
Burner Shutdown
Measures in Case of Trouble
61
Exhaust Gas Test
Ratio between O2- and CO2- for natu- Ratio between O2- and CO2- for Mean barometer readings
ral gas H (CO2max =11,86%) light oil EL (CO2max =15,40%)
Sea Mean
CO 2max – CO 2gem CO 2max – CO 2gem level barometer
O 2 = 21 × ----------------------------------------------- = % O 2 = 21 × ----------------------------------------------- = %
CO 2max CO 2max readings
[m] [mbar]
Aachen 205 991
%O2 %CO2 %O2 %CO2 % O2 % CO2 % O2 % CO2 Berlin 50 1009
0,00 11,86 3,00 10,16 0,00 15,40 3,00 13,19 Dresden 120 1000
0,10 11,80 3,10 10,10 0,10 15,33 3,10 13,12 Erfurt 315 978
0,20 11,75 3,20 10,04 0,20 15,25 3,20 13,04 Frankfurt/M. 104 1004
0,30 11,69 3,30 9,99 0,30 15,18 3,30 12,97 Hamburg 22 1011
0,40 11,63 3,40 9,93 0,40 15,11 3,40 12,89 Cologne 45 1009
0,50 11,58 3,50 9,87 0,50 15,03 3,50 12,82 Leipzig 130 998
0,60 11,52 3,60 9,82 0,60 14,96 3,60 12,75 Magdeburg 79 1005
0,70 11,46 3,70 9,76 0,70 14,88 3,70 12,67 Munich 526 955
0,80 11,41 3,80 9,70 0,80 14,81 3,80 12,60 Nuremberg 310 980
0,90 11,35 3,90 9,65 0,90 14,74 3,90 12,53 Rostock 4 1013
1,00 11,29 4,00 9,59 1,00 14,66 4,00 12,45 Stuttgart 297 984
1,10 11,24 4,10 9,53 1,10 14,59 4,10 12,38 Schwerin 59 1010
1,20 11,18 4,20 9,48 1,20 14,52 4,20 12,31 Ulm 479 960
1,30 11,12 4,30 9,42 1,30 14,44 4,30 12,23
1,40 11,07 4,40 9,36 1,40 14,37 4,40 12,16
1,50 11,01 4,50 9,31 1,50 14,29 4,50 12,08
1,60 10,95 4,60 9,25 1,60 14,22 4,60 12,01
1,70 10,90 4,70 9,19 1,70 14,15 4,70 11,94 1013,25
1000
pressure in mbar
900
2,00 10,73 5,00 9,02 2,00 13,93 5,00 11,72
2,10 10,67 5,10 8,97 2,10 13,85 5,10 11,64
2,20 10,61 5,20 8,91 2,20 13,78 5,20 11,57 800
atmospheric
62
SO2-content in Exhaust Gas
from Light Oil and Heavy Oil Combustion
ol.
v
by
5%
s1
ga
t
us
ha
ex
t in
en
nt
2 co
CO
]
ol.
v
by
%
s[
t ga
us
ha
ex
t in
en
nt
2 co
CO
Natural Gas
CO 2max – CO 2gem
O 2 = 21 × ----------------------------------------------- = %
CO 2max
%O2 %CO2 Air index %O2 %CO2 Air index %O2 %CO2 Air index
0,00 11,80 1,00 4,00 9,55 1,24 8,00 7,30 1,62
0,10 11,74 1,00 4,10 9,50 1,24 8,10 7,25 1,63
0,20 11,69 1,01 4,20 9,44 1,25 8,20 7,19 1,64
0,30 11,63 1,01 4,30 9,38 1,26 8,30 7,14 1,65
0,40 11,58 1,02 4,40 9,33 1,27 8,40 7,08 1,67
0,50 11,52 1,02 4,50 9,27 1,27 8,50 7,02 1,68
0,60 11,46 1,03 4,60 9,22 1,28 8,60 6,97 1,69
0,70 11,41 1,03 4,70 9,16 1,29 8,70 6,91 1,71
0,80 11,35 1,04 4,80 9,10 1,30 8,80 6,86 1,72
0,90 11,29 1,04 4,90 9,05 1,30 8,90 6,80 1,74
64
O2, CO2, Lambda Conversion Table
Liquid Gas
CO 2max – CO 2gem
O 2 = 21 × ----------------------------------------------- = %
CO 2max
%O2 %CO2 Air index %O2 %CO2 Air index %O2 %CO2 Air index
0,00 13,80 1,00 4,00 11,17 1,24 8,00 8,54 1,62
0,10 13,73 1,00 4,10 11,11 1,24 8,10 8,48 1,63
0,20 13,67 1,01 4,20 11,04 1,25 8,20 8,41 1,64
0,30 13,60 1,01 4,30 10,97 1,26 8,30 8,35 1,65
0,40 16,54 1,02 4,40 10,91 1,27 8,40 8,28 1,67
0,50 13,47 1,02 4,50 10,84 1,27 8,50 8,21 1,68
0,60 13,41 1,03 4,60 10,78 1,28 8,60 8,15 1,69
0,70 13,34 1,03 4,70 10,71 1,29 8,70 8,08 1,71
0,80 13,27 1,04 4,80 10,65 1,30 8,80 8,02 1,72
0,90 13,21 1,04 4,90 10,58 1,30 8,90 7,95 1,74
65
O2, CO2, Lambda Conversion Table
CO 2max – CO 2gem
O 2 = 21 × ----------------------------------------------- = %
CO 2max
%O2 %CO2 Air index %O2 %CO2 Air index %O2 %CO2 Air index
0,00 15,40 1,00 4,00 12,47 1,24 8,00 9,53 1,62
0,10 15,33 1,00 4,10 12,39 1,24 8,10 9,46 1,63
0,20 15,25 1,01 4,20 12,32 1,25 8,20 9,39 1,64
0,30 15,18 1,01 4,30 12,25 1,26 8,30 9,31 1,65
0,40 15,11 1,02 4,40 12,17 1,27 8,40 9,24 1,67
0,50 15,03 1,02 4,50 12,10 1,27 8,50 9,17 1,68
0,60 14,96 1,03 4,60 12,03 1,28 8,60 9,09 1,69
0,70 14,89 1,03 4,70 11,95 1,29 8,70 9,02 1,71
0,80 14,81 1,04 4,80 11,88 1,30 8,80 8,95 1,72
0,90 14,74 1,04 4,90 11,81 1,30 8,90 8,87 1,74
66
O2, CO2, Lambda Conversion Table
CO 2max – CO 2gem
O 2 = 21 × ----------------------------------------------- = %
CO 2max
%O2 %CO2 Air index %O2 %CO2 Air index %O2 %CO2 Air index
0,00 15,90 1,00 4,00 12,87 1,24 8,00 9,84 1,62
0,10 15,82 1,00 4,10 12,80 1,24 8,10 9,77 1,63
0,20 15,75 1,01 4,20 12,72 1,25 8,20 9,69 1,64
0,30 15,67 1,01 4,30 12,64 1,26 8,30 9,62 1,65
0,40 15,60 1,02 4,40 12,57 1,27 8,40 9,54 1,67
0,50 15,52 1,02 4,50 12,49 1,27 8,50 9,46 1,68
0,60 15,45 1,03 4,60 12,42 1,28 8,60 9,39 1,69
0,70 15,37 1,03 4,70 12,34 1,29 8,70 9,31 1,71
0,80 15,29 1,04 4,80 12,27 1,30 8,80 9,24 1,72
0,90 15,22 1,04 4,90 12,19 1,30 8,90 9,16 1,74
67
Exhaust Gas Test
The exhaust gas loss can be calculated The exhaust gas loss can be calculated
q A = exhaust gas loss in %
as follows: as follows:
t A = exhaust gas temperature
in °C
t L = combustion air temperature
in °C
CO2 = volumetric content of carbon
dioxide in %
In any case of trouble proceed with Pilot burner Adjust ignition 3. Pump oil delivery failure
checking the basic conditions for a failure. gas pressure
proper operation of the boiler Cause Remedy
system: Ignition gas Search for
1.Is electric power available? valve does not cause and elimi- Shut-off valves Open valves.
2.Is fuel oil contained in the tank? open. nate closed.
3.Is ther any gas pressure? Defective Replace Filter blocked by Clean filter or
4.Are the shut-off valves opened? solenoid. dirt. replace cartridge.
5.Are all control and safety instruments Filter leaks. Replace filter
such as boiler thermostat, water
supply failure cut-out, limit switches, Oil lines leak. Retighten scre-
2. Motor running failure wed unions; tigh-
etc. properly set?
ten oil lines.
Cause Remedy
1. Ignition failure Suction valve Remove and
Motor protection Check and leaks. clean or replace.
Cause Remedy relay and fuses. replace if
required. Direction of rota- Check irection of
Ignition elec- Adjust tion of pump. rotation.
trode short cir- electrodes. Air pressure Check and
switch not replace if Damaged gear- Replace pump.
cuit. box.
changed over or required.
Wide ignition Adjust defective. Reduced pump Replace pump.
electrode electrodes. output.
spacing. Defective motor. Replace motor.
68
Trouble Shooting Instructions
69
ELCO GmbH
Customer Service: D-64546 Mörfelden-Walldorf
ELCOTHERM AG
CH - 7324 Vilters
70