DUAL FUEL BURNERS TD/TAD4 GENERAL INFORMATION AND OPERATING MANUAL. 1 of 165

Transcription

1 DUAL FUEL BURNERS TD/TAD4 GENERAL INFORMATION AND OPERATING MANUAL 1 of 165

2 Revision Table Operating Instructions For TD/TAD4 Dual Fuel Burner Rev No. Description Date By Emergency stop information added - section 5.9 Exploded drawings revised section R.S June 13 2 of 165 TD/TAD4 Manual Rev 4

3 Operating Instructions For TD/TAD4 Dual Fuel Burner `TD/TAD` SERIES DUAL FUEL BURNERS GENERAL INFORMATION AND OPERATING MANUAL IMPORTANT Throughout this publication Dunphy Combustion Limited are referred to as `The Company`. The manual, which is supplied with every burner, should be read prior to the installation of the unit. While giving information on the site work involved and on the burner commissioning procedure, the content cannot include all of the data which may be necessary to achieve the design output of a burner to a particular appliance because of the wide variety of heating and process plant for which the burner is suitable precludes this. The Company strongly advises that the commissioning of the burners is carried out by Dunphy trained engineers and points out that it may be impossible to impart all the necessary information to enable others to do so. Under all circumstances the provisions of The Health and Safety at Work Act 1974 are the most important consideration and if any doubts exist concerning the safe operation of the burner, The Company should be contacted for advice. This provision also applies to the legislation of countries to which the burners may be exported. Where equipment, not of The Company`s supply, is used in conjunction with the burners, reference should be made to specific instructions or regulations governing the installation and use of such equipment. The Company gratefully acknowledges the permission of component suppliers and others to reproduce data sheets and technical information in this manual. For reliable and efficient operation of the burner, it is essential that regular maintenance is carried out in accordance with the instructions contained in the text of this manual. The fact that a burner may be under warranty does not absolve the user from the responsibility for this and inadequate maintenance may lead to claims, made under guarantees of materials or performance being denied IF IN DOUBT - ASK! Information contained in this manual is given without any responsibility on the part of the company for the consequences of the actions of persons making use of such information. Equipment is supplied strictly under the terms of The Company s current `Conditions of Supply` which are printed on the reverse of order acknowledgements and delivery notes. Copies are available on request. June 13 3 of 165 TD/TAD4 Manual Rev 4

4 Operating Instructions For TD/TAD4 Dual Fuel Burner Contents 1 General Information General Working parameters Fuels Fuel Tanks Filtration Ring Main Pumps Pipe Runs Burner Connection Burner Filtration Pressure Regulation Oil Line Connections Burner construction Burner details and power curve General arrangement details High low/modulating burners on gas, high low on oil Electronic modulation burners (M RT) TD Multi Fuel Low Nox Burner General Arrangement TD420 Multi Fuel Low Nox Burner General Arrangement TAD420 Multi Fuel Low Nox Burner General Arrangement Installation Burner Mounting Gas Valve mounting Burner fitted with Unibloc Burner fitted with Siemens VGD40 gas valve Fuel oil installations Pump Connections Pump Priming Gas installation Electrical connections Inverter Connection Ventilation requirements Combustion Head Settings High / Low Burners Modulating Burners Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head Modulating TD Burners Fitted With Low NOx Multi-Pipe Gas Head Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil Modulating TD Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil Modulating Burners Fitted With Bio - Gas Head Nozzle Adjustment Gas Head Multipipe Gas Nozzle adjustment Adjustments and Operating Principles High/Low burners (HL) High / Low Gas High / Low Oil Pneumatic Modulating burners (M and M-sc) on Gas, High / Low on Oil Electronic Modulation burners (M RT) Oil Operating System Modulating Burners ART 114 and ART 1400 Nozzles ART114 Burner Gun ART 1400 Burner Gun Oil Operating System Modulating Burners ART 106 Nozzle Oil Operating System Modulating Burners Multi-Oil Nozzles Oil Operating System High/Low Burners Multi-Oil Nozzles Oil Operating System Air / Steam Atomising Fuel Pumps and Motors Operation & User Interface The Display / Keypad Start -up Sequence June 13 4 of 165 TD/TAD4 Manual Rev 4

5 Operating Instructions For TD/TAD4 Dual Fuel Burner 5.3 Modulation Normal mode Local mode Non-volatile lockout Ratiotronic 6000 Inverter interface additional information Post Purge Operation Emergency Stop Component Setup Parameters Ratiotronic Danfoss VLT FC RWF A97 Default Burner Settings Commissioning Basic settings Start Gas Heat Input Pre-commissioning Commissioning High Low and Pneumatic Modulation burners - Firing on Gas Dry run Check for leaks through the automatic gas valve Check rotation of burner fan motor Check for correct control sequence Firing the burner Combustion values and results Adjustment of Gas Proving Pressure Switch Oil Firing Setting the Firing Rate, High / Low Oil Burners Electronic Modulating Burners Gas Butterfly Valve Oil Metering Valve Adjustment of air pressure proving switch Ratiotronic programming Setting the servo motors Burner Commissioning Combustion values and results Burner Maintenance Schedule Opening the Burner Minor Maintenance Major Maintenance Dismantling and Re-assembly of Burners Faults and fault finding Ratiotronic 6000/ Useful Information Exploded Diagram & Spare Parts List Modulating Oil Modulating Gas Setup Modulating Oil Modulating Gas with DH2 Pump (TD420 Only) High Low Oil High Low Gas Setup (TD410 Only) Modulating Gas High Low Oil Setup (TD410 Only) Multi-Oil Multi-Gas Exploded Diagram TD410 Low NOx Combustion Head Assembly TD Low NOx Combustion Head Assembly TD410 Combustion Head Assembly TD Combustion Head Assembly DN65 Unibloc DN80 Unibloc DN100 Unibloc VGD40.65 Assembly for Pneumatic Modulating and High Low Burners VGD40.80 Assembly for Pneumatic Modulating and High Low Burners VGD Assembly for Pneumatic Modulating and High Low Burners VGD40.65 Assembly for Electronic Modulating Burners VGD40.80 Assembly for Electronic Modulating Burners VGD Assembly for Electronic Modulating Burners Component Information LFL1.333 Burner Control Box June 13 5 of 165 TD/TAD4 Manual Rev 4

6 Operating Instructions For TD/TAD4 Dual Fuel Burner 12.2 RWF 40 Burner temperature controller Unibloc Unibloc General Arrangements mm Ratiotronic Unibloc exploded diagram and parts list mm Ratiotronic Unibloc with pilot exploded diagrams and parts list mm Ratiotronic Unibloc exploded diagrams and parts list mm Ratiotronic Unibloc with pilot exploded diagrams and parts list mm Ratiotronic Unibloc exploded diagrams and parts list mm Ratiotronic Unibloc with pilot exploded diagrams and parts list Butterfly Gas Valve General Arrangement Exploded Diagram Siemens VGD20 and VGD40 Gas Valve Blocks Siemens SKP actuators VPS 504 Valve Proving System Variotronic VT Oil Metering Valve General Description Construction Valve Maintenance Changing Seals Adjustment of the valve Installation of the valve Valve Drive Exploded Diagram DH Series Pump Pressure Regulation Technical Data Summary Installation Operation Maintenance Fault Finding Oil Flow Diagrams June 13 6 of 165 TD/TAD4 Manual Rev 4

7 1 General Information Operating Instructions For TD/TAD4 Dual Fuel Burner During commissioning, all adjustments to the burner must be made in accordance with the boiler manufacturer's instructions and these must include checking of flue gas temperature, average water temperature and CO2 or CO concentration. 1.1 General Burners must be checked at the time of delivery and any deficiencies or damage immediately reported to the carrier or supplier. The company will make good any defects or replace missing items strictly in accordance with their current conditions of supply. The company has a policy of continuous development and therefore reserve the right to make changes, without notice, in burner or other specifications. Burners carrying the same model number may have major differences in their detailed specification, such as draught tube lengths to suit the dimensions of a particular appliance, which makes it impossible to give, in a single publication, precise information on the whole range of applications. Data is readily available from the company and can be supplied on application. Please give the burner serial number when requesting information. All TD series burners are manufactured and tested to European Standards BS EN676: 2003 & A2:2008 Automatic forced draught burners for gaseous fuels, Definitions, requirements, testing, marking and EN 267 Forced draught oil burners Definitions, requirements, testing, marking It is essential that appliance and burner combinations are correctly matched. If any doubt exists about the suitability of a particular combination the installer must check with the manufacturers. If a burner is to be fitted to an existing boiler, maximum combustion efficiency can only be achieved if all heat transfer surfaces are cleaned prior to the installation. Generally `TD` series burners are not suitable for use in areas of high humidity or in explosive atmospheres, but special units suitable for use in adverse situations can be manufactured to a customer's specific requirements. Details of special units are available, on request, from the Dunphy sales department. 1.2 Working parameters Temperature Relative Humidity 0 to +50 C 60-90% non-condensing Atmospheric Air Pressure will generally be in the range of 950 to 1100mbar, but this will change with altitude, if there are any queries please consult the Dunphy technical department. 1.3 Fuels 'TD / TAD' Series of burner must only be used with the fuels specified on the burner data plate and in the case of gas, the pressure must not, under any circumstances, drop below the stated minimum operating level. The burner is also optimised for use with 35 sec diesel oil. B100 Bio-diesel must not be used on a standard burner. When using B100, it must be specified at time of order. Special pumps, valves and seals are used when burning B100. June 13 7 of 165 TD/TAD4 Manual Rev 4

8 1.3.1 Fuel Tanks Operating Instructions For TD/TAD4 Dual Fuel Burner Fuel storage tanks must be positioned to maintain a positive head to burners or ring main pumps, regardless of the oil level in the tank. Vertical and horizontal storage tanks should be mounted on concrete plinths in accordance with local, national or any environmental standards that may apply. The fuel lines and fuel filtration system must be sized to prevent any possibility of vacuum occurring in the pump suction ports. If a positive head of oil is not maintained, there is a possibility that cavitations will occur within the fuel pump. As a general guide, the fuel storage tanks must be mounted at least one meter above the ring main fuel pumps which should be sited as close as possible to the tank discharge Filtration Duplex fuel filtration is recommended to the ring main pumps, this will allow for maintenance without shutdown of the ring main system, during normal operation of the plant Ring Main Pumps The ring main pumps should be sized to give 100 to 150% over the burner pumps fuel requirements. Pumps must be fitted with an internal relief valve set at a maximum of 3 bar for pump protection. Manual isolation valves should be fitted to the pump inlet and outlet pipework to allow for maintenance. It is recommended that the valves have electric switch packs fitted to them so that they can be interlocked with oil operation. It is always preferable to use duplex pumping where practical, particularly on multi-burner installations Pipe Runs Pipework should be run in a manner that allows it to be self venting and, in sections that require venting, a suitable vent or de-gassing section should be fitted. Where overhead ring mains are to be installed particular care and attention should be taken that the system can be adequately vented. Welded construction is preferable to screwed connections Burner Connection Burner connections should be provided in the ring main pipework adjacent to the boiler and close enough to allow the burner to be opened without the need to disconnect the flexible oil lines. Note: - Manual isolation valves should not be fitted on the return lines Burner Filtration Burner filtration will depend on the size of burners in question and the quality/grade of the fuel oil to be used, but good quality fuel filters, preferably of the self-clean type are recommended Pressure Regulation The Pressure regulating valve of the ring main must be of the low, or zero, hysteresis type and capable of maintaining a stable ring main pressure through the minimum and maximum flow conditions of the supply system irrespective of any change in flow volume or viscosity. A number of suppliers manufacture valves suitable for this purpose and further details are available from the Dunphy technical department. June 13 8 of 165 TD/TAD4 Manual Rev 4

9 1.3.8 Oil Line Connections Operating Instructions For TD/TAD4 Dual Fuel Burner It is essential that the final connections between the main oil supply lines and the burner fuel pump are made with flexible oil lines that are long enough to allow the burner to be swung open on its hinges without having to be disconnected. Care should be taken to ensure that the flexible oil lines do not become `kinked` as this will cause damage to the flexible and result in leakage. 1.4 Burner construction Each T series burner is constructed from 5 separate castings described as follows: Hinge In common with all other body castings, the mounting casting is manufactured from aluminium grade LM6 with the front face drilled to the dimensions given in section 1.5 of this manual suitable for mounting studs. The rear face has two external lugs which form part of the burner hinge and is drilled to accept the studs that are used to lock the burner closed. Note: The fuel pipework enters this casting and it is essential that all joints and connections on the combustion head are checked for security before the burner is hinged to the closed position. See the maintenance section for details. This casting houses the burner draught tube and combustion head along with the appropriate ignition cables and flame detection equipment. Fan case assembly This consists of two aluminium castings with machined faces, bolted together and enclosing the fan (which is sized to suit the particular burner model according to output and combustion chamber resistance). Integral with and inside the front half of the fan cases are the compressor blades; on the outside, external lugs are attached with pins and thrust bearings to the burner mounting casting to form the hinges. The rear half is tapped to take the burner lifting eye and pads are used for the attachment of the components on various models of the burner. The rear face is machined to match the air shutter assembly, which is attached to it. A differential air pressure switch, piped across the air inlet and pressure outlet of the combustion air fan is mounted on the front section. Its function is to prevent the burner from firing if a supply of combustion air is not available or to lock out the burner if the air supply is interrupted during normal running. Air shutter Combustion air is introduced through two concentric castings, one rotating about the other on a PTFE bearing surface, regulating the combustion air supply through characterised slots to accurately maintain the fuel air ratio. Close machining tolerances ensure almost zero leakage when the damper is fully closed. The characterisation of the slots also ensures very high control of the air supply at the important low fire end typically 30 degrees of movement accounts for only 10% of air throughput thus ensuring very high turndown capability. The operation of the air shutter is activated by a reversible, mains voltage, synchronous motor (on high/low burners) or a 240 (or 24V) motor with potentiometer control for fully modulating units. Adjustable rigid linkage is used and the limits of travel are set by micro switches. Final adjustments are made during commissioning. On burners fitted with electronic modulation systems the air shutter and the fuel valves will all be manufactured with individual drive motors controlled by the modulation system. June 13 9 of 165 TD/TAD4 Manual Rev 4

10 Operating Instructions For TD/TAD4 Dual Fuel Burner On burners which have air inlet silencers as standard a 0-10 scale is fitted to indicate the opening of the air shutter (not the firing rate) and nylon support bearings ensure that the travel is as smooth as possible. Burner Motor The burner (fan) motor is a continuously rated 2-pole unit with class 'F' insulation, sized according to the application. The motor is mounted the inside of the inner shutter thus allowing 100% heat recovery from the motor into the combustion air offering efficiency ratings greater than EFF1. This also ensures inherently quiet operation from the burner. Combustion Air Fan Mounted directly onto the motor shaft and positioned within the fan case assembly, the fan supplies combustion air via the compressor vanes and mounting casting to the combustion head. Due to the 'T' burner requirement for extremely low vibration and noise levels the fans are manufactured and balanced to the very highest standards (ISO ). All fans are colour coded according to size. Combustion Head The air for combustion passes from the burner fan at a pressure related to the resistance of the boiler, down the draught tube to the combustion head. The latter is an assembly of components which cause the gas to be discharged into the air flow in such a way that optimum mixing takes place. Many types of combustion head are available depending on appliance geometry, gas type, available gas pressure, NOx level requirement etc Note: On any burner, an almost infinite combination of combustion head components may be used to achieve optimum efficiency and a flame shape to suit a very wide range of heat-raising appliances. Burner Control Cabinet Standard burners are supplied with a dust resistant damp-proof cabinet mounted on the side of the burner. In many cases all the burner controls are fitted within the burner control cabinet (figure 1). In more complicated installations, this cabinet would house a terminal strip (figure 2) which would then interface to a control desk via flying leads. Figure 1 Figure 2 June of 165 TD/TAD4 Manual Rev 4

11 Operating Instructions For TD/TAD4 Dual Fuel Burner Control desks are available in wardrobe type style (figure 3) or desk type style (figure 4). These can vary in complexity and are able to house a whole host of burner/boiler controllers, water levels controls, inverters, plc etc... Figure 4 Figure 3 Air Inlet Silencer Because of their design characteristics, 'T' series burners operate at very low noise levels, however, further reduction of these levels can be made by fitting air inlet silencers which are designed to cover the air shutter castings. The standard foam lined silencer typically offers sound levels in the region of 80dBA. An optional Snorkel type silencer is available which will reduce sound levels to below 75dBA. Silencers can also be tailored to suit ducted air supplies, filters or additional acoustic attenuation. For extremely sensitive installations, 'Acoustic Shrouds' which cover the entire burner can be individually designed to suit most applications. Quotations are available on request. Typical Acoustic Shroud Burner fitted with 'Snorkel' Silencer June of 165 TD/TAD4 Manual Rev 4

12 1.5 Burner details and power curve BURNER *1 Based on Nat. Gas C.V 10.4 kw/m3 *2 - Fitted with a Ratiotronic 6000 System Firing Rate kw GAS VOLUME (m3/hr)*1 TYPE MIN MAX MIN MAX Mod Gas High / Low Oil FIRING MODE OPTIONS High / Low Electronic Modulation *2 TD410Z TD415Z TD420Y Fan Motor KW Pump Motor kw Voltage Hz Ph Running Current Starting Current Amp 48 Amp Amp 64 Amp Amp 88 Amp 12 of 165

13 1.6 General arrangement details High low/modulating burners on gas, high low on oil High Low and Pneumatic Modulation burners both use air/gas ratio valves (details can be found in the component section of this manual). They have built-in governors thus not requiring an external governor for gas pressures up to 350mbar. In this configuration the gas valve requires two signals from the burner - the air pressure of the burner and furnace resistance of the boiler. The furnace resistance is monitored with a stainless steel piece of pipe which is projected into the furnace along the side of the burner head. This will require an additional hole or notch in the boiler mounting plate to accommodate see mounting detail. TD Burners with VGD40 Gas Valve 13 of 165

14 Operating Instructions For TD/TAD4 Dual Fuel Burner Electronic modulation burners (M RT) Electronic modulation burners are fitted with on/off gas valves and electronically controlled butterfly valves for the gas regulation. The gas valve is generally a Unibloc (see component section for details) however other valves can also be used depending on site details or customer preference. An additional electronically controlled oil metering valve is fitted for oil regulation see principle of operation section for more details. TD Burners with Unibloc Gas Valve June of 165 TD/TAD4 Manual Rev 4

15 TD420 Burners with Unibloc Gas Valve Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

16 1.6.3 TD Multi Fuel Low Nox Burner General Arrangement Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

17 1.6.4 TD420 Multi Fuel Low Nox Burner General Arrangement Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

18 1.6.5 TAD420 Multi Fuel Low Nox Burner General Arrangement Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

19 2 Installation Operating Instructions For TD/TAD4 Dual Fuel Burner 2.1 Burner Mounting Care must be taken when mounting the burner not to damage the mounting gasket. The furnace pipe (where fitted) is generally positioned at 12 o clock on the mounting flange and care must be taken not to damage it during the mounting process. Note: - Ensure that the burner mounting gasket is correctly fitted when fixing the burner to the appliance. This gasket creates a gas-tight seal between the boiler and burner and also insulates the burner mounting casting. It is important to check that the burner draught tube projection into the combustion chamber conforms to the appliance manufacturers instructions. Non standard draught tube projections are available on request; - please consult the Dunphy sales dept. In general, for reverse flame boilers the draught tube projection into the combustion chamber should be between 50 and 100mm. For other boilers the burner draught tube should finish flush or slightly proud of any boiler refractory or insulation. Low NOx heads should be projected into the furnace by at least mm. If there is any doubt about the correct projection into the combustion chamber, the appliance manufacturer must be consulted. June of 165 TD/TAD4 Manual Rev 4

20 2.2 Gas Valve mounting Operating Instructions For TD/TAD4 Dual Fuel Burner Burner fitted with Unibloc The Unibloc gas valve is a heavy item and will require two persons to lift it into position and secure in place using bolts provided. The Unibloc is shipped pre - connected. Please consult electrical wiring diagram for electrical connections. Governor shown is supplied with every burner using a Unibloc gas valve and should be installed according to guidelines illustrated below and approximately 10 pipe diameters upstream of the gas valve. Pipe work and isolating valve are supplied by others. Important: The installer must install a 90 turn type isolation ball valve next to or in close proximity to the burner and capable of rapid operation. The manual valve must be capable of operating at a pressure equal to 1.5 times the maximum supply pressure and where possible must be orientated in such a way that when the valve closes the handle must fall from the vertical to the horizontal. The valve must have mechanical end stops to prevent the ball valve from going below the 0 point or above the 90 point. The gas supply pipework must be adequately supported to prevent undue stress on the burner casing or the gas train components. Gas supplies greater than 500mbar must be governed down to a suitable gas pressure below 500mbar using a CE approved high pressure gas governor. The gas governor or should be fitted as per manufactures instructions, copies available on request. Typical Gas train installation is shown on the right June of 165 TD/TAD4 Manual Rev 4

21 VGD Gas Valve Orientation Operating Instructions For TD/TAD4 Dual Fuel Burner Unibloc Orientation Governor Orientation Fit governor in accordance with manufactures instructions. June of 165 TD/TAD4 Manual Rev 4

22 Operating Instructions For TD/TAD4 Dual Fuel Burner With the gas isolation valve next to the burner closed, a pressure test should be carried out on the main gas supply pipe work and all connections checked with a suitable, non corrosive leak detection fluid. If the installation is supplied with a gas pressure above 1 bar (14.5p.s.i.g.) and contains plant with a heat input of more than 2MW, local authorities will generally ask for the fitting of remotely operable fire valves. The national or other standards in countries to which the burners may be exported must be identified and met Burner fitted with Siemens VGD40 gas valve The Siemens gas valve is a heavy item and will require two persons to lift it into position and secure in place using bolts provided. 8mm blue and black PVC pipes plus fitting are supplied with the burner. The blue line must be connected between the Air connection on the SKP75 actuator and the air pulse line situated on the top flat of the burner hinge section. The black line must be connected between the Combustion Chamber connection on the SKP75 and the furnace line connection protruding through the mounting flange of the burner. Important: The installer must install a 90 turn type isolation ball valve next to or in close proximity to the burner and capable of rapid operation. The manual valve must be capable of operating at a pressure equal to 1.5 times the maximum supply pressure and where possible must be orientated in such a way that when the valve closes the handle must fall from the vertical to the horizontal. The valve must have mechanical end stops to prevent the ball valve from going below the 0 point or above the 90 point. The gas supply pipework must be adequately supported to prevent undue stress on the burner casing or the gas train components. The Siemens gas valve has a built-in governor and is suitable for gas pressures up to 500mBar. Gas supplies greater than 500mbar must be governed down to a suitable gas pressure below 500mbar using a CE approved high pressure gas governor. The gas governor or should be fitted as per manufactures instructions, copies available on request. June of 165 TD/TAD4 Manual Rev 4

23 2.3 Fuel oil installations Operating Instructions For TD/TAD4 Dual Fuel Burner Fuel oil installations must comply with the following British Standards or equivalent local, national or international standards. BS799 BS5410 BS2869 Oil burning equipment Code of practice for oil firing Fuel oils for non marine use Installations must conform to local Bye-laws and regulations which should be identified by application to the local planning authority Pump Connections The burner is supplied with two flexible hose lines and is connected as shown in illustration below. OIL RETURN FLEXIBLE CONNECTION B OIL RETURN FLEXIBLE CONNECTION A OIL RETURN FLEXIBLE CONNECTION A OIL RETURN FLEXIBLE CONNECTION B PUMP TYPE CONNECTION A CONNECTION B DH1 Series 2.4 Pump Priming 3 / 4 " BSP 3 / 4 " BSP DH2 Series 1 BSP 1 BSP In order to ensure correct start-up for DH series oil pumps, the following guidelines should be adhered to. 1. Ensure that the oil supply to the pump has been properly bled through and that no air is present in the oil supply. The flexible oil lines should be fully flooded before connection to the pump. 2. Check that all isolating valves are open and that the oil supply temperature and pressure are correct. 3. Lubricate the pump by removing the pressure gauge plug and filling the pump with suitable thin lubricating oil. 4. Check pumps rotation. June of 165 TD/TAD4 Manual Rev 4

24 Operating Instructions For TD/TAD4 Dual Fuel Burner 5. Turn pump slow until all air has been vented both from the pump itself and the burner pipework, and the system is fully flooded. 6. The pump can now be put into operation. 2.5 Gas installation In all cases, gas installation work must be carried out by approved members of Gas Safe All relevant standards of The British Standards Institute, IGEM Standard's and the equivalent European Standards must be adhered to. Note: The national or other standards in countries to which the burner may be exported to must be identified and adhered to. 2.6 Electrical connections All electrical installation work must be carried out in accordance with the I.E.E. wiring regulations 17th Edition 2008, with further reference to the Health and Safety Executives `Memorandum of Guidance on the Electricity at Work Regulations 1989 ( H.S.E. Booklet HS[R]25 ) Take note of the I.E.E. requirement for bonding main gas supply pipework to earth. Connections to all terminals and the appliance should be made in accordance with the wiring diagram supplied with each burner. The final part of the electrical cable run must be made in flexible conduit, long enough to enable the appliance door to be opened. Ensure that the mains electrical supply to the burner is protected by a suitably sized fuse. Connections to all terminals and the appliance should be made in accordance with the wiring diagram supplied with each burner, using suitable fixed wiring installation (incorporating means of disconnection) in accordance with local and national wiring regulations. 2.7 Inverter Connection Burner motor connections can be found in dedicated aluminium enclosure situated on the side of the burner control panel. Wiring diagram shows how to connect the inverter to this enclosure. The earth leakage current from the frequency converter exceeds 3.5mA. To ensure excessive leakage current conforms to EN/IEC , an earth wire of at least 10mm 2 or two separate earth ground wires are used. Warning: Touching the electrical parts may be fatal even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as load-sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Before touching any electrical parts, wait at least: please consult the inverter manual. 2.8 Ventilation requirements June of 165 TD/TAD4 Manual Rev 4

25 Operating Instructions For TD/TAD4 Dual Fuel Burner Provision must be made for an adequate supply of combustion and ventilating air to be available when all access doors, fire doors and windows are closed. Air supply fans or flue dilution systems must be interlocked to prevent operation of the burner(s) in the event of fan failure or shutdown. To ensure an adequate supply of combustion air, the room in which the burner(s) are installed should have permanent ventilation according to local or national standards. June of 165 TD/TAD4 Manual Rev 4

26 3 Combustion Head Settings Operating Instructions For TD/TAD4 Dual Fuel Burner On burners fitted with standard 'Z' and 'Y' type nose cones, the dimension 'A' between the end of the burner nose cone and the front face of the flame plate, can be altered by releasing the three, M6 locking nuts inside the draught tube, and sliding the cone forwards / backwards, along its adjustment slots until the required setting is obtained. Important Notes: Factory setting of gas flow is as shown on the following combustion head arrangement drawings. Position of gas nozzles must be finalised at commissioning to suit the particular boiler in which the burner is fitted. When using low NOx heads, the projection must be at least mm past the boiler refractory (into the furnace). June of 165 TD/TAD4 Manual Rev 4

27 3.1 High / Low Burners Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

28 3.2 Modulating Burners Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

29 Operating Instructions For TD/TAD4 Dual Fuel Burner 3.3 Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head June of 165 TD/TAD4 Manual Rev 4

30 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

31 Operating Instructions For TD/TAD4 Dual Fuel Burner 3.1 Modulating TD Burners Fitted With Low NOx Multi-Pipe Gas Head June of 165 TD/TAD4 Manual Rev 4

32 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

33 Operating Instructions For TD/TAD4 Dual Fuel Burner 3.2 Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil June of 165 TD/TAD4 Manual Rev 4

34 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

35 Operating Instructions For TD/TAD4 Dual Fuel Burner 3.1 Modulating TD Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi- Oil June of 165 TD/TAD4 Manual Rev 4

36 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

37 3.2 Modulating Burners Fitted With Bio - Gas Head Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

38 3.3 Nozzle Adjustment Operating Instructions For TD/TAD4 Dual Fuel Burner Gas Head The Combustion head is attached to the gas inlet on the body. The gas flows through the gas annulus and through the 4 holes in the gas nozzle. The gas flow can be altered by adjusting the restrictor band, shown below. Undo the four M5 screws, rotate the band to open or close the nozzle holes Multipipe Gas Nozzle adjustment The Combustion head is attached to the gas inlet on the body. The gas flows through the 6 gas pipes and through the holes in the gas nozzles. The gas flow can be altered by rotating the nozzles to direct the gas either towards or away from the centre of the burner. The gas nozzles can also be adjusted along the multipipe head, this will either move the gas holes closer or further away from the flameplate. To carry out the above adjustments, loosen the 2x M4 grub screws on each nozzle securing the nozzle to the pipe. June of 165 TD/TAD4 Manual Rev 4

39 4 Adjustments and Operating Principles 4.1 High/Low burners (HL) High / Low Gas Operating Instructions For TD/TAD4 Dual Fuel Burner High low control is classed as the simplest form of control for a burner of this size. It relies on a high/low thermostat monitoring either the temperature or pressure of an appliance which in turn via the control box will drive the air damper servo between the high fire position and low fire position. Gas regulation is performed by means of an air/gas ratio valve. The valve senses the amount of combustion air available and regulates an internal gas governor to output sufficient gas to ensure good combustion at both high and low firing rates. This also gives the feature of maintaining good air gas ratio (therefore good efficiency) between high and low fire positions which wouldn t be the case on a standard 2 stage gas valve. When the burner is switched off the air damper will fully close preventing any chimney buoyancy cooling of the appliance. Cam IV of the air servo motor is used to set the ignition position of the air damper. Once the burner is lit and has stabilised the air damper will move to either the low fire (CAM III) or high fire (CAM I) position depending on load demand. Travel is adjusted by means of cam operated limit switches. The cam switch gears within the motor can be disengaged by pushing the brass push button. Releasing the gears allows adjustment of the air damper without connection to the drive unit. Adjustments of cams can be made by hand or with the key which is housed within the motor cover. Gas flow adjustments are made using the controls V (for high fire adjustment) and N (for low fire adjustment) see commissioning section for details and gas valve manufacture details shown in component section. Cam I... High Fire Gas Cam II...Air Damper Fully Closed Cam III...Low Fire Gas Cam IV......Ignition Position For Gas Cam V...High Fire Oil Cam VI... Low Fire Oil Cam VII...V2 Oil June of 165 TD/TAD4 Manual Rev 4

40 4.1.2 High / Low Oil Operating Instructions For TD/TAD4 Dual Fuel Burner Atomisation of the fuel is by two separate nozzles, one for low fire and the second for high fire. The oil supply to each nozzle passes through one of twin solenoid shut-off valves and the burner output is determined by the size of nozzle and the pressure setting of the fuel pump regulator. Normally, two nozzles of the same size will be used to give a total output equivalent to the maximum continuous rating (MCR) of the appliance, and, At low fire, approximately 50% of MCR. Dissimilar nozzles can however be fitted to alter the low fire to high fire ratio. Nozzles of different spray angle and patterns are used on various furnace configurations in order to give the appropriate flame shape. The whole of the oil system is protected by a pump discharge valve ( PDV ) which is fitted on the oil pressure outlet of the pump and which closes, isolating the oil system when the burner is not running. When the control box reaches the firing stage, the air damper drives to the low fire position (CAM VI) and the ignition spark is switched on. Both the PDV and first stage solenoid valve (V1) are energised simultaneously releasing oil through the first stage nozzle, which is ignited by the spark from the ignition electrode. The oil pressure should now be adjusted, by means of the pump pressure regulating screw, to give approximately 50% of the MCR of the appliance and the air shutter adjusted to give optimum combustion efficiency. As the control box reaches the high fire stage, the air damper motor drives the air shutter to the high fire position and sends a signal to the second stage oil valve (V2). As a safety measure, the second stage oil valve is energised through an auxiliary switch in the air damper motor (CAM VII). The logic of this arrangement is that the air damper must be in the `high fire` position before the second stage solenoid can open, thus ensuring that an oil rich condition cannot occur. When a burner is switched from high to low fire, the closing speed of the solenoid will always be faster than that of the air damper, so the combustion will again remain air-rich. The oil pressure should now be adjusted, by means of the pump pressure regulating screw, to give the full MCR of the appliance and the air shutter adjusted to give optimum combustion efficiency. Nozzle throughputs are given in the table on the following page. It is essential that, on completion, the burner is tried a number of times to ensure that changeover between low and high fire is smooth and that the flame does not `lift off`. PDV PG V1 P PUMP S R OIL SUPPLY GC V2 LFN HFN V1 V2 PDV PG GC LFN HFN P S R Low Fire Valve NC High Fire Valve NC Pump Discharge Valve Pressure Gauge Gauge Cock Low Fire Nozzle High Fire Nozzle Pump Pressure Suction Return OIL LINE SCHEMATIC FOR LIGHT OIL DUAL FUEL BURNERS HIGH LOW WITH TWIN NOZZLES June of 165 TD/TAD4 Manual Rev 4

41 HIGH/LOW BURNERS NOZZLE PRESSURE/OIL THROUGHPUT TABLES Operating Instructions For TD/TAD4 Dual Fuel Burner Rated Flow at U.S. GALLONS PER HOUR LITRES PER HOUR 100 P.S.I. PRESSURE P.S.I. PRESSURE BAR G.P.H. L/hr One U.S. Gallon = Litres One U.S. Gallon = Imperial Gallons June of 165 TD/TAD4 Manual Rev 4

42 Operating Instructions For TD/TAD4 Dual Fuel Burner 4.2 Pneumatic Modulating burners (M and M-sc) on Gas, High / Low on Oil M burners use the same air gas ratio valve as used on the high low burners and therefore connections to the valve are the same and principle of operation is also the same. The control system however does differ in that the position of the air damper can be done in incremental steps via a 3-stage switched input. This is generally performed using a temperature or pressure controller, Dunphy use an RWF40 controller to perform this function see component section for more details, however any suitable controller with a 3-stage output would suffice. The RWF40 can either be mounted on the burner panel or remotely somewhere within the customer panel. Air damper and gas valve adjustments are the same as with the High Low burner above. Principle of Operation for Oil is the same as in Section Burners with extension M-sc are modulating burners with inverters fitted to control the speed of the fan. This has the benefit of higher turn-down, improved combustion, much quieter operation and energy saving. Its set point is derived from a potentiometer situated and mechanically connected to the back of the air damper motor. As the control box drives the air damper motor up and down according to the appliance load characteristics, the potentiometer sends a proportional signal to the inverter which makes the fan go faster or slower depending on whether more or less air is required. The inverter is setup in the factory and there is no need to make any adjustments. 4.3 Electronic Modulation burners (M RT) ME burners are fitted with electronic control systems which have direct control over the air damper and gas butterfly valve using high precision digital servo motors. The Air / Gas or Air / Oil ratio is defined by a profile curve which is programmed into the controller during the commissioning phase. Ratiotronic 6000 series controllers are generally fitted to these burners however Siemens LMV2.. series and LMV5.. series controllers may also be offered as an alternative. ME burners are relatively complex products and it is recommend that they are commissioned by qualified Dunphy personnel. Documentation on these controllers is too lengthy to incorporate into this document and therefore is supplied as a separate manual. Both manuals must be used in conjunction with each other when commissioning and operating the burner. June of 165 TD/TAD4 Manual Rev 4

43 Operating Instructions For TD/TAD4 Dual Fuel Burner Oil Operating System Modulating Burners ART 114 and ART 1400 Nozzles Atomisation of the oil is by means of a single nozzle which works on the spill-back principle. The nozzle fits into a hydraulic nozzle line assembly that allows oil from the pump outlet to circulate through the nozzle and back through the metering valve to the pump return when the burner is ready to fire, N.C. solenoid valves 4 & 5 open allowing oil to flow through the nozzle. the return path from the nozzle line flows through a metering valve and back to the return of the pump through a safety shut off valve. The oil volume is controlled by a metering valve 6, in the spill line restricting the amount of spilled oil and therefore increasing the volume that passes through the nozzle for combustion. Control of both the metering valve and the air shutter is achieved by means of independent servo motors which are positioned by the electronic control system. Key 1) Nozzle Line Assembly 2) Nozzle 3) Oil Pump (Dunphy) 4) Pump Discharge Valve - Normally Closed 5) Pump Discharge Valve - Normally Closed 6) Oil Metering Valve (Dunphy) 7) Pressure Gauge Bar 8) Gauge Clock 9) Non - Return Valve 10) Test Point 11) Flexible Oil Line (Supplied Loose) 12) Low Oil Pressure Switch (Optional) 13) High Oil Pressure Switch 14) Manual Isolation Valve with Switch Packs (when fitted), interlocked with oil select on burner. June of 165 TD/TAD4 Manual Rev 4

44 4.3.2 ART114 Burner Gun Operating Instructions For TD/TAD4 Dual Fuel Burner To set the spring tension of the piston, the spring tension screw is set 20mm from the back chamber as shown above. The piston stroke is setup using the piston limit screw. The screw is first fully screwed in so that the piston cannot move; the screw is then moved out by 10mm to set the stroke. The nozzle has a vent on the back chamber to allow the piston to move, DO NOT BLOCK THE VENT ART 1400 Burner Gun The ART1400 nozzle has a set spring tension and piston stroke; no adjustments can be made to the operation of the burner gun. The nozzle has a vent on the back chamber to allow the piston to move, DO NOT BLOCK THE VENT. June of 165 TD/TAD4 Manual Rev 4

45 CAPACITY TABLES FOR TYPE ART114/1400 RETURN FLOW NOZZLES Operating Instructions For TD/TAD4 Dual Fuel Burner Supply pressure - 30 bar Viscosity - 5cSt (35 secs Redwood) Maximum output with return closed. ATOMIZER NUMBER RETURN PRESSURES IN BAR OUTPUTS IN KILOGRAMS/hr PUMP RECOMMENDED MAXIMUM MAX OUTPUT TURN-DOWN RATIO June of 165 TD/TAD4 Manual Rev 4

46 4.3.4 Oil Operating System Modulating Burners ART 106 Nozzle Operating Instructions For TD/TAD4 Dual Fuel Burner Atomisation of the oil is by means of a single nozzle which works on the spill-back principle. From the schematic diagram below it can be seen that when the oil supply is admitted to the nozzle by the two main oil valves, the flow can either pass through the nozzle into the furnace or can return down the spill line to the pump return. The control of the oil volume is achieved by a metering valve in the spill line restricting the amount of `spilled` oil and therefore increasing the volume that passes through the nozzle for combustion. Control of both the metering valve and the air shutter is achieved by means of a modulating motor which is positioned by potentiometer according to the control signal. On burner shutdown both the main safety shut off valves and the return safety shut off valves close simultaneously to isolate the nozzle and reduce any possibility of oil spillage into the furnace. June of 165 TD/TAD4 Manual Rev 4

47 NOZZLE NUMBER Operating Instructions For TD/TAD4 Dual Fuel Burner CAPACITY TABLES FOR TYPE ART 106 RETURN FLOW NOZZLES Supply pressure - 20 bar Viscosity - 5 cst ( 35 secs Redwood ) RETURN 3 bar NOZZLE OUTPUT Kg/hr CLOSED RETURN TURN-DOWN RATIO Note:- Turn-down ratio will increase with supply pressures ART 106 SPILL-BACK NOZZLE BLOCK ART 106 SPILL-BACK OIL NOZZLE OIL RETURN OIL SUPPLY ART 106 SPILL-BACK NOZZLE BLOCK AND NOZZLE June of 165 TD/TAD4 Manual Rev 4

48 4.3.5 Oil Operating System Modulating Burners Multi-Oil Nozzles Operating Instructions For TD/TAD4 Dual Fuel Burner Atomisation of the oil is by means of three nozzles which work on the spill-back principle. The nozzle fits into the hydraulic nozzle line assemblies that allow oil from the pump outlet to circulate through the nozzles and back through the metering valves to the pump return when the burner is ready to fire, two PDV N/C solenoid valves open allowing oil to flow through the nozzles. The return path from the centre nozzle flows through metering valve MV1, while the three outer nozzle flows through MV2, they then join a common oil line, passing through two N/C safety shut off valves, and back to the return of the pump. The oil volume is controlled by the metering valves (MV1 and MV2) in the spill line restricting the amount of spilled oil and therefore increasing the volume that passes through the nozzle for combustion. Control of both metering valves and the air shutter is achieved by means of independent servo motors which are positioned by the electronic control system. June of 165 TD/TAD4 Manual Rev 4

49 4.3.6 Oil Operating System High/Low Burners Multi-Oil Nozzles Operating Instructions For TD/TAD4 Dual Fuel Burner Atomisation of the oil is by mean of three outer nozzles and one central nozzle. The pump pressure is set at 25 Bar, the two pressure regulators controlling the pressure to all four nozzles are set at 10 Bar. On Low fire V1, V2 and V3 are open, V4 is closed. This allows oil to pass through all four nozzles at a pressure of 10 Bar. On High fire, V1,V2, V3 and V4 are opened, oil at 10 Bar flows through the centre nozzle, oil flows through the three outer nozzles at 25 Bar through V4 bypassing the pressure regulator through V3. June of 165 TD/TAD4 Manual Rev 4

50 4.3.7 Oil Operating System Air / Steam Atomising Operating Instructions For TD/TAD4 Dual Fuel Burner The TA principle of operation is that oil, carrying both heat and hydraulic energy, enters a mixing chamber in the nozzle where it is mixed with the streams of the atomising fluid (compressed air or steam), carrying kinetic energy and in the case of steam, heat energy. The combination of forces resulting from the directional differences between the oil flow, steam flow and the kinetic and heat energy forces cause an emulsification process to take place. The oil/steam or oil/air mixture then impinges on the nozzle pintle plate which gives secondary atomisation, and finally passes out of the nozzle orifice which imparts a swirling motion into the finely atomised spray. The emerging angle of the spray can vary according to the type of nozzle fitted. The oil supply from the pump passes through the pump discharge valve, the pre-heater the metering valve and the nozzle line and goes back to the pump return via the V1 main oil valve and a nonreturn valve. When the burner is switched on, the oil pre-heater (When fitted) is energised and the oil temperature is raised to the required level. When the oil reaches the required temperature the burner motor/pump is started and the oil is allowed to circulate through the burner pipework until the correct temperature is attained throughout the system. The check stat then sends a signal to the control box which starts the firing cycle by opening the air damper to the high fire position. When the control box reaches the firing stage, the air damper drives to low fire position and the ignition spark is switched on. Both V1 normally open and V1N normally closed nozzle line solenoids are energised together releasing oil through the nozzle, and the atomising medium solenoid (PV) opens to allow air or steam into the nozzle mixing chamber. The resulting mixture is ignited by the spark from the ignition electrode or by a pilot gas ignition system. The main oil pressure is set, by means of the pump pressure regulating screw and the atomising oil pressure adjusted at the metering valve to give the correct low and high fire oil throughputs. The atomising medium pressure must be adjusted at the pressure regulator (RG) in conjunction with the oil pressure to ensure smooth light up and optimum combustion throughout the firing range. The air shutter is adjusted to give optimum combustion efficiency throughout the firing range. June of 165 TD/TAD4 Manual Rev 4

51 Operating Instructions For TD/TAD4 Dual Fuel Burner Fuel Pumps and Motors All `TD` series burners are supplied with a separate, directly coupled fuel pump and drive motor. Details of the various sizes of pumps and motors are given in the table below. BURNER TYPE PUMP TYPE MOTOR SIZE (kw) RPM TD410ZHL DH Fig 71 TD410ZM DH or Fig 71 TD415YM DH Fig 71 DRIVE COUPLING OIL LINE CONNECTIONS 3 / 4 " BSP 3 / 4 " BSP 3 / 4 " BSP TD420YM DH Fig 71 1" BSP June of 165 TD/TAD4 Manual Rev 4

52 5 Operation & User Interface Operating Instructions For TD/TAD4 Dual Fuel Burner 5.1 The Display / Keypad The display is a 2 line, 20 characters per line, dot matrix vacuum fluorescent type allowing the use of plain text messages for display parameters. The keypad is a membrane construction with tactile keys to give a positive feedback of the actuation. The SCROLL keys are used to view boiler and burner status data during normal running conditions. In commission mode, these keys select option parameters, which are adjusted by the UP/DOWN keys. The UP/DOWN keys are used to adjust the fire rate in manual modulation mode. In commission mode, they are used for data value selection. Alternate key functions when in commission mode. Key EK LOW FIRE FUEL SELECT BURNER O-I MUTE / RESET AUTO / HAND DATA COM Function Selects Engineers Key mode. Pressing this key will force the burner to Low fire until the key is pressed again to release the burner to modulate. Changes Fuel/Profile. If the fuel is changed when the burner is firing, the burner will go off then restart firing the new fuel selection. Sets the burner On or Off and enables changes between normal and local operation. Note: Terminal PE9 must be ON for this switch to start the burner. Press this key to mute (open) the alarm relays, and then hold the key down for approximately three seconds to reset the cleared faults. Selects auto or manual burner modulation. In manual mode the UP/DOWN keys are used to alter the fire rate. Selects different data types on the display window. Changes operation to commission mode via a pass-code. June of 165 TD/TAD4 Manual Rev 4

53 5.2 Start -up Sequence Operating Instructions For TD/TAD4 Dual Fuel Burner When a fuel selection is made and the burner select signal is given to start up the burner, the controller performs the sequence described below. If a gas profile is selected and the safety valve proving function is selected, the controller will perform safety valve pressure proving concurrently with the start-up sequence. State no. State name Description 0. Non-volatile lockout All fuel valve outputs are OFF and the Alarm output is ON until muted. The burner is held in this state until all faults are removed. 1. Burner off The burner is checked to make sure that it has switched off completely. Testing includes - main fuel safety valves closed, no flame signal and no air pressure signal. The controller will remain in this state until there is a call for heat from the PID system. 2. Wait for purge The controller waits for both a burner select (PE9 ON) and a fuel/air profile to be selected. Progression to stage 3 or 5 maybe held off by external influences, e.g. Digital Communications control or digital input controlled by an external circuit. 3. Open fuel valve If gas firing and safety valve proving are selected, the gas valve servo motor is moved open for five seconds to allow any gas in the test section to be vented easily during the proving sequence. 4. Hold fuel valve The fuel motor is held in position until step 1 of the safety valve proving sequence (open main valve 2, or vent valve) is completed. 5. Prove closed positions 6. Prove air pressure 7. Prove purge positions If gas is selected, the gas valve proving sequence begins. The fuel and air motors are moved to closed position until they stop. The final positions are compared with the closed positions stored in memory when the profile is commissioned. The burner motor output is set ON and air pressure prove time (t1) is initiated. The selected motors are moved open towards the purge position. If the fan start early option parameter has been set then the motors will not move until the option time has expired. When the air pressure prove time has elapsed, the air pressure switch must give a pressure signal or the controller will lockout the burner and move to stage 0. If primary air is selected, then both primary and secondary air pressure signals must be ON to prove air pressure. The selected motors are driven open until they reach their commissioned purge position. June of 165 TD/TAD4 Manual Rev 4

54 Operating Instructions For TD/TAD4 Dual Fuel Burner State State name Description no. 8. Pre-purge Once the servo motors are at their purge positions the controller starts the pre-purge (t2) timer. 9. Move to ignition positions When t2 has elapsed, the fuel and the air motors are moved to the ignition position for the selected profile. The controller will wait at the ignition positions while the gas valve proving sequence finishes before progressing to stage Pre-ignition Once the fuel and air motors are at their ignition positions, the ignition transformer output is energized and pre-ignition time (t3) is starts. 11. Pilot ignition Once t3 has elapsed the ignition transformer remains on, first main valve if required for pilot flame gas, and pilot valve outputs are energised and the first safety time (t4) is started. If firing on oil and ignition selected to be with both pilot and main valve, use timing in the start-up sequence table for main valve 1. If firing on oil and ignition with main valve is not selected the pilot ignition will occur with only the pilot valve, use timing in the start-up sequence table for main valve Pilot ignition interval When t4 is complete, a flame must be detected or the controller will lockout the burner and move to stage 0. The ignition transformer may optionally be on or off (See option parameter 14.6). 13. Main ignition Once the pilot interval time (t5) has elapsed, the second (and first if not already open) main valve output(s) for gas, or main oil valve output for oil is energized and the second safety time (t6) is started. If firing on oil and ignition with main valve was selected the main oil valve will have already opened for pilot ignition. The ignition transformer may optionally be on or off (See option parameter 14.6). A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage Wait for Main flame established 15. Moving to low fire When t6 has expired, the pilot valve output is turned off. If permanent pilot is selected and the burner is firing on gas, then the pilot will remain open with the main valves. Main flame interval time (t7) is started. A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage 0. When t7 has elapsed, the flame is considered established and the fuel and air motors are moved from their ignition positions to their low fire positions and held at those positions for the duration of the Low Fire Hold Time (t8). A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage 0. June of 165 TD/TAD4 Manual Rev 4

55 Operating Instructions For TD/TAD4 Dual Fuel Burner State State name Description no. 16. Modulation When t8 has elapsed the fuel and air motors are modulated according to the demand placed on the burner. If the fuel selection is changed or the burner on signal (PE9) is removed, the main valve output(s) are turned off. A flame and air pressure signal must be detected or the controller will lockout the burner and move to stage Move to postpurge If Post Purge is not selected then the controller returns to state 1 to wait for another start-up. If Post Purge has been selected then the fuel servo motor is moved to its closed position, and the selected air motor(s) are moved to their post purge position(s). 18. Post-purge When the air drive(s) have reached their post purge positions then the Post Purge Time (t9) is started. When t9 has elapsed, the burner motor is turned off and the controller returns to state 1 to wait for another start-up. 5.3 Modulation During stage 16 (modulation), the controller will position the fuel and air motors within the programmed profile appropriate to the requirement for heat. The controller has 2 modes of operation using the standard RATIOTRONIC modulation function, Normal and Local. The mode of operation is set via the keypad by pushing the Burner ON/OFF key and selecting the mode. Using the programmable block function (option) within the controller it is possible for the modulation control to be generated with customised options, these are not covered in the standard manual. 5.4 Normal mode In Normal mode, the modulation rate is determined by the internal PID control settings, Manual modulation from the keypad, or by one of the following remote influences: Auxiliary modulation input, Digital set point selection Serial communications Comview or Lead/Lag. 5.5 Local mode In Local mode, the modulation rate is determined by either the internal PID settings or Manual modulation via the UP/DOWN keys. External modulation inputs and set point selection inputs are ignored. When Local1 is displayed the burner is running using the Set point 1 PID settings. When Local2 is displayed the burner is running using the Set point 2 PID settings. 5.6 Non-volatile lockout Non-Volatile lockouts cannot be cleared without operator intervention and are remembered in the event of power being removed from the controller. A non-volatile lockout will occur under the following conditions: June of 165 TD/TAD4 Manual Rev 4

56 If any step of the gas proving sequence fails In stages 1-9 (inclusive) if a flame is detected In stages (inclusive) if a flame is not detected In stage 4 if the air pressure switch goes high (air pressure present) Operating Instructions For TD/TAD4 Dual Fuel Burner In stages 7-18 (inclusive) if the air pressure switch goes low (air pressure not present) In stages 5, 7 and 8, stages (inclusive) and stage 18 if a motor is not in the correct position In any stage, if an internal or external fault not previously mentioned occurs which may affect the safe operation of the burner 5.7 Ratiotronic 6000 Inverter interface additional information The Ratiotronic 6000 may have an optional daughter board within the main enclosure to allow control of 1 or 2 inverter drives (daughter board dependent). Optionally the daughter board is also available to allow feedback to be taken from directly from encoders measuring the speed of the relevant motor, fan or pump shaft. There is also an option to allow the speed of an additional rotary device to be monitored as an encoder input. When not configured to control an inverter, the 4-20mA outputs may be configured to transmit system variables as current outputs. There are special wiring requirements for inverter feedback. 5.8 Post Purge Operation If a post combustion purge is selected (with option parameter 7.9), a normal shutdown post purge will be performed at low fire. The drives will move to the low fire position (if not already there) and the post-purge time will then start. If the burner has turned off because the fuel profile selection has been removed (i.e. set to NONE), no post-purge will be performed. If the burner locks out at or after ignition, and a post-purge time has been entered, the controller will also attempt a post purge. For a flame failure fault, the controller will attempt to post purge at high fire. For all other faults, the drives will stay at the positions they were in when the lockout occurred. In both cases, the post-purge time starts at the moment the lockout occurs the controller does not wait for drives to position before starting the post-purge time. June of 165 TD/TAD4 Manual Rev 4

57 Operating Instructions For TD/TAD4 Dual Fuel Burner 5.9 Emergency Stop The emergency stop or e-stop is a safety mechanism used to shut off the burner in an emergency situation in which it cannot be shut down in the usual manner. Unlike a normal shut-down switch/procedure, which shuts down the burner in an orderly fashion and turns it off without damaging it, an e-stop is designed and configured to a) completely abort the operation at all costs and b) be operable in a manner that is quick, simple (so that even a panicking user with impaired executive function can operate it), and, usually, c) be obvious even to an untrained operator or a bystander. The e-stop features a removable barrier to provide protection against accidental activation. June of 165 TD/TAD4 Manual Rev 4

58 6 Component Setup Parameters Operating Instructions For TD/TAD4 Dual Fuel Burner Before the commissioning process of the burner can take place, there are certain components like the Ratiotronic 6000, inverter (when fitted), etc, which will need to be setup. The burner should be factory set; however, if the parameters have been erased for whatever reason, then this section can be used as a starting point. Please note that a fuel / air profile will not have been setup. Please also note that this parameter set should be used in conjunction with the manual. 6.1 Ratiotronic 6000 Option Value Description Comments 0.1 xxx Site passcode last 3 digits of burner serial number Serial communications control address Reset hours run Language Select IsoComsAddress IsoComsSetting Power up option 5=ignore alarms for 5 seconds at power up Keyboard auto/manual enable Fault mute input enable External profile select enable Gas valve proof of closure select Oil valve proof of closure Second airflow switch (primary air) enable Safety time configuration set Force Mode Input Drive 0 name not used Drive 1 name gas servo motor Drive 2 name oil servo motor Drive 3 name air servo motor Drive 4 name VSD drive Drive 5 name Drive 6 name Drive 7 name Drive 8 name Drive 9 name Drive 0 serial number not used 3.1 xxxx Drive 1 serial number - Gas Servo 1st 4 Digits of Ser No 3.2 xxxx Drive 2 serial number - Oil Servo 1st 4 Digits of Ser No 3.3 xxxx Drive 3 serial number - Air Servo 1st 4 Digits of Ser No Found on side of servo motor 3.4 VSD1 Drive 4 serial number Drive 5 serial number Drive 6 serial number Drive 7 serial number Drive 8 serial number Drive 9 serial number Drive 0 profile assignment not used Drive 1 profile assignment profile Drive 2 profile assignment profile Drive 3 profile assignment profiles = Drive 4 profile assignment profiles = 3 June of 165 TD/TAD4 Manual Rev 4

59 Operating Instructions For TD/TAD4 Dual Fuel Burner Drive 5 profile assignment Drive 6 profile assignment Drive 7 profile assignment Drive 8 profile assignment Drive 9 profile assignment Drive 0 rotation 0 = anti-clockwise / 1 = clockwise Drive 1 rotation 0 = anti-clockwise / 1 = clockwise Drive 2 rotation 0 = anti-clockwise / 1 = clockwise Drive 3 rotation 0 = anti-clockwise / 1 = clockwise Drive 4 rotation 0 = anti-clockwise / 1 = clockwise Drive 5 rotation 0 = anti-clockwise / 1 = clockwise Drive 6 rotation 0 = anti-clockwise / 1 = clockwise Drive 7 rotation 0 = anti-clockwise / 1 = clockwise Drive 8 rotation 0 = anti-clockwise / 1 = clockwise Drive 9 rotation 0 = anti-clockwise / 1 = clockwise Fuel train for profile 1 gas Fuel train for profile 2 oil Fuel train for profile Fuel train for profile Fan on early time Air Proving time Pre-purge time Do not reduce this timing Pre-ignition time Do not extend this timing Pilot ignition time Do not extend this timing Pilot hold time Do not extend this timing Main ignition time Do not extend this timing Ignition hold time Do not extend this timing Low fire hold time Do not extend this timing Post purge time Do not reduce this timing Ignition spark output check Flame failure response time Extend false flame response time Inverter control accuracy 0 = low / 1 = high Inverter error tolerance 0 = low / 1 = high Inverter closed loop gain Inverter stop time Inverter acceleration time VSD1 speed encoder scaler VSD2 speed encoder scaler Low speed cup limit Oil warning speed Gas pressure sensor select 1 valve proving via sensor, 0 valve proving via pressure switches Gas pressure sensor span Gas pressure nominal Parameters 10.2, 10.5 and 10.6 will give a valve proving time of approx 40secs. This is an optimised set of figures do not alter Gas pressure low limit Gas pressure high limit Test volume June of 165 TD/TAD4 Manual Rev 4

60 Operating Instructions For TD/TAD4 Dual Fuel Burner Maximum permissible leakage rate Vent valve select Valve proving select 1 VPS enabled, DO NOT DISABLE VPS Power Time Photocell / IR flame detection select Pilot flame threshold photocell Main flame threshold photocell Centre frequency photocell Frequency pass ban photocell 13.0 x UV/Ionisation flame detection 1=non-shuttered/2=shuttered 13.1 x Pilot flame threshold non-shuttered = 20, shuttered = Main flame threshold Primary fault relay Limit relay Oxygen + fuel temperature limit relay Permanent gas pilot select Pilot with/without main valve select 0 = without / 1 = with Direct ignition on oil Spark termination Oil pump relay function 1 = light oil / 2 = heavy oil Extended oil pilot Modulation input sensor type 2 = 4-20mA 15.1 x Modulation input decimal places 0 = temp / 1 = pressure Modulation input zero value 15.3 xx Modulation input span value default: temp = 150, pressure = x Set-point display units 1 = bar / 3 = deg c Boiler high safety limit Modulation time Bumpless transfer Low fire before off 0 = no / 1 = yes Go back to pilot Allow profile swap online HV input 12 alarm/lockout function Boiler high limit stat, on PE HV input 13 alarm/lockout function Fan trip, on PE xx HV input 12 display message 11 high temp, 13 high pressure, on PE HV input 13 display message Fan interlock, on PE Relay 1 output function (display unit) PR1,PR2,PR Relay 2 output function (display unit) PR5,PR6,PR Relay 3 output function (display unit) PR7,PR8,PR Relay 4 output function (controller) PD6,PD7,PD Relay 5 output function (controller) PD4,PD5,PD Relay 6 output function (controller) PD1,PD2,PD Relay 7 output function (26 = VSD1 start circuit) PZ17-PZ Relay 8 output function PZ15-PZ LV input 1 function PB9-PB LV input 2 function PB9-PB LV input 3 function PB9-PB LV input 4 function PB9-PB LV input 5 function Low Gas Pressure PB14-PB LV input 6 function High Gas Pressure PB14-PB16 June of 165 TD/TAD4 Manual Rev 4

61 Operating Instructions For TD/TAD4 Dual Fuel Burner LV input 7 function PB14-PB LV input 8 function PB5-PB LV input 9 function PB5-PB LV input 1 message PB9-PB LV input 2 message PB9-PB LV input 3 message PB9-PB LV input 4 message PB9-PB LV input 5 message Low Gas PB14-PB LV input 6 message High Gas PB14-PB LV input 7 message PB14-PB LV input 8 message PB5-PB LV input 9 message PB5-PB Set-point select input 1-7 or Boiler shutdown input 1-7 or Low fire hold input 1-7 or Oxygen trim disable input 1-7 or Ignition wait input 1-7 or Purge hold input 1-7 or Purge time start input 1-7 or Analogue input 5 option aux mod input Lead boiler select 1-7 or Set-point 1 enable 21.1 x Set-point 1 control value default: temp = 80, pressure = Set-point 1 proportional value default: temp = 1, pressure = Set-point 1 integral time Set-point 1 derivative time Set-point 1 control limit type Deviation Set-point 1 low limit control value default: temp = 10, pressure = 0.5 Burner On 0.5 below SP Set-point 1 high limit control value default: temp = 10, pressure = 0.5 Burner Off 0.5 above SP Remote set-point 1 zero (4mA) value Remote set-point 1 span (20mA) value Set-point 2 enable Set-point 2 control value Set-point 2 proportional value Set-point 2 integral time Set-point 2 derivative time Set-point 2 control limit type Set-point 2 low limit control value Set-point 2 high limit control value Mod Max Enable Input Mod Max Value Warming enable Warming limit Warming time Number of sequence lag boilers enables into sequencing st lag boiler address nd lag boiler address rd lag boiler address Lead assign type Lag on rate June of 165 TD/TAD4 Manual Rev 4

62 Operating Instructions For TD/TAD4 Dual Fuel Burner Lag on delay Lag off rate Lag off delay Analogue output 1 function VSD1 overrides if selected Analogue output 1 zero (4mA) value Analogue output 1 span (20mA) value Analogue output 2 function VSD2 overrides if selected Analogue output 2 zero (4mA) value Analogue output 2 span (20mA) value Analogue output 3 function Analogue output 3 zero (4mA) value Analogue output 3 span (20mA) value Oxygen probe interface serial number Oxygen probe calibration offset value Oxygen probe calibration gain value Oxygen probe calibration gas concentration Flue & inlet temp sensor units Oxygen input function Oxygen probe calibrate enable Boiler transport delay Reset oxygen trim profile Automatic trim commissioning Limit modulation range Trim type for profiles Trim limit default Trim limits Trim integral gain Trim proportional gain default Trim proportional gain Inlet temp sensor serial number Hydrocarbon ratios for each fuel respectively Calorific values of fuels / profiles 1-4 respectively Boiler radiated heat loss Flue temperature alarm select Flue temperature low alarm value Flue temperature high alarm value Oxygen alarm select Oxygen low alarm value at low fire Oxygen low alarm value at high fire Oxygen high alarm at low fire Oxygen high alarm at high fire Second oxygen probe select June of 165 TD/TAD4 Manual Rev 4

63 Operating Instructions For TD/TAD4 Dual Fuel Burner Second oxygen probe calibration offset Second oxygen probe calibration gain Maximum oxygen variation Maximum flue temp variation Second oxygen probe calibration enable Set real time clock Set year Set month Set day of month Set day of week Set hours Set minutes Set seconds Clear fault history Erase/Restore enable Erase command Restore command June of 165 TD/TAD4 Manual Rev 4

64 6.2 Danfoss VLT FC 102 Operating Instructions For TD/TAD4 Dual Fuel Burner PNU NAME FACTORY DEFAULT DCL SETTING 0-20 DISPLAY LINE 1.1 REF % ANALOG INPUT DISPLAY LINE 1.2 MOTOR AMPS 0-22 DISPLAY LINE 1.2 POWER KW 0-23 DISPLAY LINE 2 FREQUENCY HZ 0-24 DISPLAY LINE 3 KW/H COUNTER SPEED RPM 0-40 LCP HAND START ENABLE DISABLE 0-41 LCP STOP ENABLE DISABLE 0-42 LCP AUTO START ENABLE DISABLE 0-43 LCP RESET ENABLE 1-00 CONFIG MODE OPEN LOOP 1-03 VT CHARACTER AEO FUNCTION 1-20 MOTOR POWER xxxkw Use Motor Dataplate Info 1-22 MOTOR VOLTAGE 400 V 1-23 MOTOR FREQUENCY 50 HZ 1-24 MOTOR CURRENT xxx A Use Motor Dataplate Info 1-25 MOTOR NOM SPEED xxxx RPM Use Motor Dataplate Info 1-29 AUTO MOTOR ADAPT NO AMA ENABLE COMPLETE 1-90 MOTOR THERM PROTECTION ETR TRIP 1 THERMISTOR TRIP 1-93 THERMISTOR SOURCE NONE ANALOG INPUT MIN REFERENCE 0.0 HZ 20.0 HZ 3-03 MAX REFERENCE 50.0 HZ 3-13 REFERENCE SITE HAND / AUTO REMOTE 3-15 REFERENCE 1 SOURCE ANALOG INPUT RAMP UP TIME 45.0 SEC 15 SEC 3-42 RAMP DOWN TIME 90.0 SEC 20 SEC PNU NAME FACTORY DEFAULT DCL DEFAULT 4-10 MOTOR SPEED DIRECTION BOTH DIRECTIONS CLOCKWISE 4-12 MOTOR SPEED LOW LIMIT 0.0 HZ 20.0 HZ 4-14 MOTOR SPEED HIGH LIMIT 50.0 HZ 4-16 TORQUE LIMIT MOTOR MODE 110 % 150 % 4-18 CURRENT LIMIT 110 % 150 % 4-19 MAX OUTPUT FREQUENCY 100 HZ 4-50 WARNING LOW CURRENT 0.0 A 4-51 WARNING HIGH CURRENT 99.0 A 4-52 WARNING LOW SPEED 0.0 RPM 4-53 WARNING HIGH SPEED 3000 RPM 5-01 TERMINAL 27 MODE INPUT 5-10 TERMINAL 18 DIGITAL INPUT START 5-11 TERMINAL 19 DIGITAL INPUT NO OPERATION 5-12 TERMINAL 27 DIGITAL INPUT COAST INVERSE 5-13 TERMINAL 29 DIGITAL INPUT JOG NO OPERATION 5-14 TERMINAL 32 DIGITAL INPUT NO OPERATION 5-15 TERMINAL 33 DIGITAL INPUT NO OPERATION 5-40 RELAY 1 FUNCTION ALARM RUNNING 5-41 RELAY 1 ON DELAY 0.01 SEC June of 165 TD/TAD4 Manual Rev 4

65 Operating Instructions For TD/TAD4 Dual Fuel Burner 5-42 RELAY 1 OFF DELAY 0.01 SEC 5-40 RELAY 2 FUNCTION RUNNING ALARM 5-41 RELAY 2 ON DELAY 0.01 SEC 5-42 RELAY 2 OFF DELAY 0.01 SEC 6-12 TERMINAL 53 MIN SCALING 4.00 ma 6-13 TERMINAL 53 MAX SCALING ma 6.14 TERMINAL 53 LOW REF/FEEDBACK VALUE 6.15 TERMINAL 53 HIGH REF/FEEDBACK VALUE 6-20 TERMINAL 54 MIN SCALING 0.07 V 6-21 TERMINAL 54 MAX SCALING 10.0 V 6-50 TERMINAL 42 ANALOG OUT SPEED 0 HIGH LIMIT SPEED 4-20mA 6.51 TERMINAL 42 MIN SCALING 0 % 40 % 6.52 TERMINAL 42 MAX SCALING 100 % 100 % 8.30 PROTOCOL FC MODBUS RTU 8.31 ADDRESS BAUD RATE BAUD 9600 BAUD 8.33 PARITY/STOP BITS EVEN PARITY/1 STOP BIT NO PARITY/1 STOP BIT June of 165 TD/TAD4 Manual Rev 4

66 6.2.1 RWF A97 Default Burner Settings Operating Instructions For TD/TAD4 Dual Fuel Burner SETTING FACTORY DEFAULT DCL SETTING REMARKS C F C C SCL SCH SCL SCH SPL SPH OFF OFF OFF DF DF OLLO OLH DTT AL HYST PB DT RT DB TT HYS HYS HYS Q H P SP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP PRESSURE TEMP User definable June of 165 TD/TAD4 Manual Rev 4

67 7 Commissioning Operating Instructions For TD/TAD4 Dual Fuel Burner 7.1 Basic settings It is essential that heat output of the appliance is known in order that the correct fuel input can be calculated and set. If there is any doubt at all with regard to the appliance rating, the manufacturer should be consulted before the burner is fired. The calorific value of the fuel must be known and measurement of the fuel input should be by meter wherever possible. Do not leave the burner firing at a rate which is known to be or which may be excessive, this will result in damage to the appliance. The nett flue gas temperature should be taken throughout the process of setting combustion. The figure will vary according to the construction of the appliance but will normally be in the range of 180 to 250 C gross. if in doubt what this figure should be, please consult the boiler/appliance manufacturer. Calculation of burner firing rate ( output ). Qf Qn k [ kw] Qf = Burner Firing Rate ( Output ) kw Qn = Boiler nominal thermal output ( kw ) k = Boiler Efficiency Calculation of Gas Throughput at Nominal Boiler Output Qn Vb HU k m 3 [ * h ] Vb = Gas Throughput ( Fuel Input ) m 3 h. Qn = Boiler nominal thermal output ( kw ) k = Boiler Efficiency HU = Calorific Value of Fuel under Normal Conditions ( kwh/m 3 ) Calculation of Gas Throughput for Boiler Firing Rate Qf Vb HU [ m 3 h] Vb = Gas Throughput ( Fuel Input ) m 3 h. Qf = Burner Firing Rate ( Output ) kw HU = Calorific Value of Fuel under Normal Conditions ( kwh/m 3 ) Burner output ( kw ) = Boiler output ( kw ) Boiler efficiency The indicating scale on the air damper motor is calibrated so that zero represents the fully closed position for the air damper. The indicated low fire and high fire positions will be the result of the June of 165 TD/TAD4 Manual Rev 4

68 Operating Instructions For TD/TAD4 Dual Fuel Burner adjustments described below, there are no pre-determined positions applicable to a particular burner. The scale reading only represents the air damper opening and not the firing rate! Adjustments to the burner combustion head (for example the position of the flame ring in the nose cone) may be necessary during the `setting up` of a burner. Details of the settings for a particular burner, firing a given make of boiler, cannot be given in a manual of a realistic size, however, standard basic settings are given in section 3 of this manual. The size and relative position of the flame ring to the cone will have an appreciable effect on the volume and velocity of air passing over the flame ring and this must be taken into consideration when setting the combustion efficiency, with adjustments made as necessary. Adjustment of the flame plate in relation to the nose cone can be made by loosening the screws holding the nose cone in place and moving the nose cone backwards or forwards. After adjustments have been made, ensure that screws are retightened and sealed in place. NOTE: ON ANY BURNER, AN ALMOST INFINITE COMBINATION OF COMBUSTION HEAD COMPONENTS AND SETTINGS MAY BE USED TO ACHIEVE OPTIMUM EFFICIENCY AND A FLAME SHAPE TO SUIT A VERY WIDE RANGE OF HEAT- RAISING APPLIANCES. THE MOST SUITABLE COMBINATION/SETTINGS MUST BE DETERMINED DURING THE COMMISSIONING PROCEDURE. 7.2 Start Gas Heat Input The table below summarises the ignition gas rates for different burner configurations. The start gas heat input must not exceed 120kW or the value given by the equation : t s x Q s 100 where: June of 165 TD/TAD4 Manual Rev 4

69 Operating Instructions For TD/TAD4 Dual Fuel Burner t s is the safety time in seconds (s): Q s is the maximum start gas heat input expressed as a percentage of the main gas rate This approximates to an ignition rate of less than one third of the maximum firing rate. If the burner is fitted with a separate pilot, the start gas heat input of the ignition burner must not exceed the value given by the equation: t s x Q s 150 where: t s is the safety time in seconds (s): Q s is the maximum start gas heat input expressed as a percentage of the main gas rate 7.3 Pre-commissioning Note: The following tests must be carried out before commissioning is started. Check that the appliance has been filled to the correct level Check that the appliance isolating valves are fully open. Where fitted, check that the flue damper is locked in the open position. Check that the flue-draught stabiliser moves freely Check that the gas supply is guaranteed and is at the correct pressure. Check that the gas meter is the correct size. Ensure that a manual gas isolation valve is positioned as close as possible to the burner and that all gas pipe work is adequately supported. Check that the external electrical connections are in accordance with the appliance manufacturers wiring instructions. Make certain that both fuel supplies and electrical supplies have been isolated. Ensure that all gas, oil and electrical connections are tight as connections may come loose during transportation. Check the electrode gap to be 3mm at the narrowest point of the ignition electrode (twin) and the tip of gas ignition electrode is 3mm away from the gas nozzle outlet. Set the firing rate control switch to `low fire` to ensure that the burner will remain at low fire after light-up. Hot water boilers - check operation of the control and limit thermostats and that the boiler has been filled with water. Steam boilers - confirm the operation of the boiler feed pump and switch, and check that the water level controls are working. After the initial firing of the boiler, do not leave the unit operating in an unmanned boiler house unless the boiler on/off control has been operated and set at a suitable figure and the flame failure system on the burner has been checked. June of 165 TD/TAD4 Manual Rev 4

70 Operating Instructions For TD/TAD4 Dual Fuel Burner 7.4 Commissioning High Low and Pneumatic Modulation burners - Firing on Gas Dry run Note: Gas leak checks must be carried out using a suitable non-corrosive leak detection fluid. Check for gas leaks on meters, governors and all mains gas supply pipe work. Ensure all pipework leading up to the burner main gas valve has been purged according to IGE/UP/1 Soundness testing and Purging of Industrial & Commercial Gas Installations Ensure that the burner manual isolation valve is closed. Check that all isolation valves in the main gas supply pipe work are open. Remove or loosen the gas inlet pressure test point on the inlet side of the gas valve and open the burner isolation valve until all air has been purged between the isolation valve and the burner gas valve. When this has been done, close the isolation valve. Note: For the following tests a digital manometer will be required Check for leaks through the automatic gas valve. Connect the manometer to the gas inlet test point on the automatic gas valve, open the manual gas isolation valve for two seconds and then close it again. The pressure shown on the manometer should remain constant Check rotation of burner fan motor Switch on mains electrical supply. Momentarily 'blip' the burner fan connector and check rotation of fan against direction of rotation sticker fixed to the rear of the burner. If motor rotates in the wrong direction, changeover two of the incoming 3 phase supply. Repeat test to ensure rotation is now correct Check for correct control sequence. Open manual gas isolation valve for two seconds and then close it again, sealing the gas between the automatic gas valve and the isolation valve. Check that all time switches, room thermostats etc are in the `on` position and that the boiler thermostat is set to the required temperature. Switch on the mains electrical supply. Select 'Gas' on the control system The control box will commence the starting sequence which, depending on the control box, will average:- Prepurge time Pre-ignition time Pilot proving time 30 seconds 3 seconds 3 seconds When the pilot proving time is reached, the automatic gas valve is energised and will release the gas trapped between the valve and the closed isolation valve. The burner will then stop because the pressure acting upon the gas pressure proving switch will be reduced due to the isolation valve being closed. Switch off the electrical supply on completion of this test. June of 165 TD/TAD4 Manual Rev 4

71 7.4.5 Firing the burner Operating Instructions For TD/TAD4 Dual Fuel Burner Ensure that the heat demand will allow an extended run, otherwise the burner may not continue to fire throughout the time required for throughput measurement or commissioning procedure. Unscrew or loosen the outlet gas pressure test point on the gas valve and connect a manometer. Open the manual gas isolation valve. Switch on the mains electrical supply and, if the control box is locked out (indicated by the reset button being illuminated) press the lockout reset button. For electrical modulation systems, please consult relevant manual. Provided all control devices, thermostats etc are in the `on` position the burner control box will start the operating sequence. For information relating to sequence of operation please refer to section 5. If the control sequence fails to start, check for correct setting of the gas pressure proving switch. The amount of gas flowing through the valve can be adjusted by using the and and is proportional to the amount of combustion air set by the air damper motor. Cam setting for the air damper have been described in section 4.1. is used to set the Low Fire rate and is used to adjust the high fire rate. A combination of the two settings will define an operating line between high fire and low fire and the valve will maintain the air/gas ratio across this range. Full information on the gas multiblock may be found in section 4. Adjustment of will have an effect on the setting of and viceversa. It may take 3 or 4 fine adjustments at both high fire and low fire to ensure good combustion at both ends. ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS Combustion values and results All combustion readings must be taken with an approved and correctly calibrated test kit. The following combustion values should be reached:- Low Fire CO content 0-20 ppm CO 2 content 9-11 % O 2 content 5.4-2% High Fire CO content 0-20 ppm CO 2 content 10-11% O 2 content 3.6-2% In all cases the CO figure should not exceed 100mg/m 3 maximum. The nett flue gas exit temperatures should be taken throughout the process of setting the combustion. The figures will vary according to the type of appliance but for shell and sectional boilers will be in the range of C gross. Always keep the exhaust flue gas temperatures within the manufacturers recommended range and ensure that the appliance is not over or under fired. Warm up the boiler, or raise steam in accordance with appliance manufacturer s instructions. June of 165 TD/TAD4 Manual Rev 4

72 7.4.7 Adjustment of Gas Proving Pressure Switch Operating Instructions For TD/TAD4 Dual Fuel Burner Loosen the screw in the gas inlet measuring point, connect a manometer and remove the clear plastic cover from the gas pressure detector. Switch on the burner and allow to fire. Close the burner manual gas isolation valve slowly until the gas pressure is reduced to 50%. Adjust the numbered black plastic ring on the gas pressure detector until the burner switches off. Switch off the mains electrical supply to the burner, remove the manometer and seal the test point screw. Open the manual gas isolation valve and switch on the burner. 7.5 Oil Firing All burners using oil as a fuel are fired before despatch as part of the standard test programme. This does not mean that the pump pressure or any other adjustment applying to the oil system is necessarily correct for the application. Commissioning of the burner must include confirming that the nozzle size and characteristics are suitable, calculating the fuel pressure required to give boiler M.C.R. and ensuring that, subject to the requirements given below, the firing rate is correctly set. The following text in included on the basis that the burner has been commissioned on gas and that the boiler or appliance controls have been set. The change - over of fuels is made by operation of the selector switch on the burner control cabinet. This selector switch controls two contactors which electrically isolate one fuel from the other. On electronic modulating burners, fuel selection can be made via the keypad. For change-over to either fuel the switch selection is made through the 'off' position which causes the burner control box to extinguish the flame before recycling. The starting cycle will not immediately commence because it will be necessary for the burner motor to slow down, reducing the air flow to a level which allows the air pressure switch to return to the 'no' air position. Note: Even on oil firing the leak detection cycle will be activated. Before changing to oil firing, ensure that the oil pump has been properly vented and flooded. No mechanical changes or re-adjustment of components are required for the burner to be changed from one fuel to another. Before the first firing on oil, it is always advisable for the availability of fuel, fire valves open etc, to be confirmed. Check that the burner will remain at low fire Setting the Firing Rate, High / Low Oil Burners Step 1 Set the Low Fire air damper motor setting to between 1 and 2 on the scale and the high fire air damper setting to between 5 and 6 on the scale. Set O2 to approx 3 on the scale. Ensure that the High / Low switch is in the low fire position and switch on the burner. Momentarily 'blip' the oil pump contactor to check for correct rotation of pump - ensure it rotates according to rotation sticker fixed to rear of the motor. If rotation is incorrect, swap June of 165 TD/TAD4 Manual Rev 4

73 Operating Instructions For TD/TAD4 Dual Fuel Burner over two pluses on the pump motor. Do not swap the mains electrical feed as this will also reverse the burner fan motor rotation. Start the burner and allow to go through pre-purge cycle. When the burner reaches its ignition position, the ignition transformer is switched on, followed by the fuel pump motor, and then the two solenoid valves, which should result in the burner lighting. Set the pump pressure to approx 25 bar. Adjust the low fire air position to give the following figures: Carbon Dioxide: 11-14% Smoke Number: 0-1 ( Excess Oxygen: 3-6% Nett Flue Gas Temperature: ºc Step 2 Allow burner to move to High Fire position. On its way to High Fire, the V2 Oil Valve will energise, thus passing oil into the second nozzle. Once at High Fire, adjust air damper to give combustion figures similar to above. Switch between Low and high Fire, checking the firing rate and combustion, ensuring that consistent figures and smooth, reliable light-up are being obtained. Listen for signs of flame instability. With the burner firing, remove and cover the photocell, ensuring that the burner goes immediately to lockout. Warm up the boiler or raise steam slowly, and in accordance with the manufacturer's instructions. After running for a reasonable amount of time, remove the combustion head and check for any oil impingement, oil leaks, or fouling at the flame plate. If necessary, make adjustments to the combustion head to cure this. Check the flame ring for indications of overheating or impingement by the oil spray. The basic, relative positions of the combustion head components are given in section 3 of this manual, but the principles to be followed are that:- 1. The ignition electrodes must be positioned so that the spark, which `strikes` at the narrowest point is blown forward by the combustion airflow on to the widest point of the `horns`. This will ensure that the arcing takes place within the cone of atomised fuel, with a consequent immediate ignition of the fuel. Note that if the electrodes are set too far forward, they will be subjected to continuous impingement by un-burnt fuel, some of which will carbonise, quickly reducing the intensity of the spark and leading to poor ignition. 2. The relative position of the flame ring must give a flame which is `anchored` on to the front face of the ring. The slotted vanes must be opened enough to allow the passage of an adequate amount of air, which because of the swirl effect imparted, will be a major stabilising factor. If the vane gap is irregular, the flame shape will be affected and soot will build up at the points which restrict the air flow. If the nozzle is too near to the flame ring, the flame will tend to `lift off`, giving very unreliable ignition and a degree of instability which will make reliable operation, especially when modulating from high to low fire. 3. The combustion head as an assembly, must be central in the draught tube, otherwise the air velocity round the outside of the flame ring ( and therefore of the flame ) will vary in June of 165 TD/TAD4 Manual Rev 4

74 Operating Instructions For TD/TAD4 Dual Fuel Burner relation to the gap through which the air is passing, causing poor flame shape and impingement on the furnace structure. 4. Where divergent ( expanded ) nose cones are used, the cone itself should be positioned relative to the flame ring and allow an adequate volume of air for combustion, but at the same time, give a velocity which is high enough to assist in shaping the flame to give optimum combustion. While the design of the combustion head is the major factor in obtaining maximum combustion efficiency, careful setting of the various component parts is also important. When a burner has been in service for a period long enough for its performance to be confirmed and before the settings have been disturbed, the relative dimensions of the combustion head components should be recorded, so that after dismantling for maintenance, correct reassembly can be assured. Set the high/low thermostat or pressure switch to a lower figure than the on/off control. The difference should take account of demand, bringing the burner back to low fire early enough to slow down any boiler pressure or temperature rise if the heat demand is less than the boiler M.C.R. and reduce the on/off cycling of the burner. Equally the burner must revert to its high fire rate in time to maintain the pressure or temperature above a figure which is determined by site conditions. June of 165 TD/TAD4 Manual Rev 4

75 7.6 Electronic Modulating Burners Operating Instructions For TD/TAD4 Dual Fuel Burner IMPORTANT! When commissioning burners fitted with Electronic Modulating Control Systems, the respective operating manuals must be followed. Only competent and trained personnel are permitted to commission burners fitted with these controls Gas Butterfly Valve Control of the gas supply to the burner is performed using a butterfly valve. material specification of blade and spindle can be altered depending on gas type, E.G. Stainless Steel can be specified for Bio-gas. Check the butterfly valve has been correctly set to zero - Please consult manual for details. More details on the butterfly valve can be found in the component section Oil Metering Valve The oil metering valve is used to control the amount of oil returning from the spill back oil nozzle line. On spill back systems, the witness mark on the inner spool piece must be set to 'B'. Set the pointer to zero - Please consult manual for details. With the pointer set to zero, this represents maximum flow through the metering valve. As the valve modulates up to 90º, the valve closes off, also closing off the return spill line from the oil nozzle line and therefore increasing the firing rate. More details on the oil metering valve can be found in the component section Adjustment of air pressure proving switch Check the air pressure proving switch and, if necessary, set to 50% of differential pressure. Example of adjustment:- Negative pressure ( ) measured Positive pressure ( + ) measured Differential pressure is - Switch off point of pressure switch is 4 mbar 5 mbar 9 mbar 4.5mbar From this point all commissioning procedures are dictated by the Ratiotronic 6000 manual. ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS June of 165 TD/TAD4 Manual Rev 4

76 7.6.4 Ratiotronic programming Operating Instructions For TD/TAD4 Dual Fuel Burner The Ratiotronic 6000 burner control system is generally pre-programmed in the factory prior to despatch. However it is important that the parameters are checked against the lists supplied with the test data supplied with the burner. The combustion engineer must be competent with such a controller and be fully trained in burner commissioning before proceeding any further. This manual must be used in conjunction with the Ratiotronic 6000 manual at all times Setting the servo motors Please refer to section 5 of the Ratiotronic manual. In general the drive servo motors are allocated as follows: Drive 1: Gas Butterfly valve Drive 2: Oil Metering Valve Drive 3: Air damper servo motor Drive 4: Inverter Burner Commissioning All burners using oil as a fuel are fired before despatch as part of the standard test programme. This does not mean that the pump pressure or any other adjustment applying to the oil system is necessarily correct for the application. Please now refer to Section 6.6 Commission Ratio Mode of the Ratiotronic 6000 manual for details on how to commission the burner Combustion values and results All combustion readings must be taken with an approved and correctly calibrated test kit. The following combustion values should be reached:- Low Fire CO content 0-20 ppm CO 2 content 9-11 % O 2 content 5-2% High Fire CO content 0-20 ppm CO 2 content 10-11% O 2 content 3.6-2% In all cases the CO figure should not exceed 100mg/m 3 maximum. The nett flue gas exit temperatures should be taken throughout the process of setting the combustion. The figures will vary according to the type of appliance but for shell and sectional boilers will be in the range of C gross. Always keep the exhaust flue gas temperatures within the manufacturers recommended range and ensure that the appliance is not over or under fired. Warm up the boiler, or raise steam in accordance with appliance manufacturer s instructions. June of 165 TD/TAD4 Manual Rev 4

77 8 Burner Maintenance Schedule Operating Instructions For TD/TAD4 Dual Fuel Burner REMEMBER! ELECTRICAL AND FUEL SUPPLIES MUST BE ISOLATED BEFORE ANY MAINTENANCE WORK IS CARRIED OUT ON THE BURNER. The following schedules are only to be taken as a guide to those persons responsible for day to day maintenance of the burners. Details of a service agreement covering the major items of routine servicing are available on request. An annual check by factory trained technicians is strongly advised. All control circuit components, fire valves and other safety devices should have a functional check at not greater than annual intervals. Maintenance and inspection of boilers or other appliances must meet the requirements of the manufacturers' schedules and of the insurers. It is usually more convenient to carry out burner maintenance after the completion of the boiler inspection or cleaning, so that the burner can be fired and the combustion reset to optimum figures. The measurements given in the various combustion head drawings in this manual are to be regarded as datum figures only. During commissioning, alterations may be made to the relative positions, or to the components themselves, to suit the particular application. Therefore, before dismantling the combustion head, take note of the measurements concerned and record them on the manual's drawings. It is important that where possible components of the same type and size are fitted as replacements. The commissioning certificate for the burner should be available, to be used as a reference for the fuel input and combustion figures which will give boiler MCR and the highest efficiency level. 8.1 Opening the Burner To open the burner, the two nuts securing the hinge section to the fan section must be removed. The burner will swing open on its hinge offering full access to all combustion head components. When necessary checks/repairs have been carried out, close up in reverse order ensuring that the locking nuts are fully tightened. June of 165 TD/TAD4 Manual Rev 4

78 8.2 Minor Maintenance Operating Instructions For TD/TAD4 Dual Fuel Burner (a) Check the operation of the flame failure system daily by deliberately locking out the burner. This can be achieved by either removing the UV cell, or on burners fitted with ionisation probes isolating the gas supply to the burner. (b) Where fitted, check and regularly clean the UV cell window with a soft cloth. (c) Inspect the burner control cabinet to ensure that all indicator lamps are serviceable. (d) Make a general check for cleanliness and security. (e) As convenient, make an inspection of the combustion head components for cleanliness, security and serviceability. (f) Check the main gas valves for external hydraulic fluid leaks. (g) Confirm the security of all linkages, locking nuts and any component parts fitted to the burner (h) Where a micro-ammeter is fitted make regular checks to confirm that the UV cell output does not significantly deteriorate. 8.3 Major Maintenance Take adequate safety precautions against the small amount of gas which escapes when gas train components are removed. Carry out all of the maintenance tasks listed above, plus the following: (a) Remove the upstream pilot valve and determine the amount of dust etc. which is present. If a substantial quantity is found, remove the upstream main gas valves from the burner and clean the seats (Unibloc only, see 'Unibloc' section of this manual for actuator removal). The Siemens valve is a sealed unit any unauthorised opening will invalidate warranty. (b) Check and clean any gas filters in the site pipework if significant quantities of dust or scale are found. Make a request to the gas region for similar work on the service filter which protects the meter (c) Confirm correct operation of electrical components, e.g. control boxes, motor starters etc and check tighten all electrical terminals. (d) The nominal life of a U/V cell is 10,000 hours, subject to regular checks of the cell output as registered on the micro-ammeter (which might indicate an earlier deterioration) the cell should be changed every third year. (e) Disconnect the air shutter linkage at the shutter spigot. Move the shutter by hand to confirm freedom of movement. Clean as necessary (the PTFE bearing surfaces need no lubrication but will require replacement when worn) (f) Inspect the refractory of the burner mounting plate. Make good any defects in refractory or sealing (g) Ensure that boiler furnace sight glasses are clean and that their sealing is flue gas-tight. (h) When the inspection and any rectification work has been completed on the burner/boiler, bring the unit up to working temperature (slowly). (i) With the boiler on line, confirm that the fuel throughput and combustion efficiency are equal to the 'commissioned' figures. June of 165 TD/TAD4 Manual Rev 4

79 8.4 Dismantling and Re-assembly of Burners Operating Instructions For TD/TAD4 Dual Fuel Burner Combustion Head Removal The combustion head can be removed, as a unit, for maintenance purposes. Before commencing refer to the combustion head drawings in the exploded diagram section at rear of this manual for relevant positions of the various components. (a) Open the burner, as described in the burner maintenance schedule. (b) Disconnect the probe/ht lead and, where a UV cell is fitted, remove this from its retaining clip and move to a safe place. (c) Loosen the jacking screw in the mounting hinge section opposite the gas entry, as shown in the illustration below. (d) Pull the nozzle line spigot out of the gas entry. (e) Withdraw the nozzle line complete, out of the blast tube. June of 165 TD/TAD4 Manual Rev 4

80 Operating Instructions For TD/TAD4 Dual Fuel Burner (f) Re-assemble in reverse order, ensuring that a new gas head seal is fitted. (g) Check the combustion head is correctly aligned in the blast tube and that the seal is gas tight. (h) Close and lock-up the burner Burner Motor Replacement (a) Disconnect the probe and ignition leads from the combustion head and withdraw them and, where necessary the UV cell from the mounting casting. (b) Disconnect air pressure switch and hinge switch cables. Ensuring that all cables are properly marked for ease of re-connection. (c) Ensure that the burner door locking nuts are fully tightened. (d) Disconnect all mains power connections and other electrical wiring between the burner panel and the boiler or other electrical panels again ensuring cables are marked. (e) Disconnect the motor wiring at the panel end (ensure that all cables are identified and that the wiring connections on the replacement motor are the same as on the original). (f) Remove the air damper drive linkage. (g) On the TD3, TD4 and TD5 burners it will be necessary to electrically disconnect the air damper modulation motor. (h) Take out the four fixing bolts and remove the modulation motor mounting bracket. (i) Using suitable lifting gear take the weight of the burner by its lifting eye. (j) Remove the ring of screws which secure the two halves of the fan case. (k) Remove the rear half of the burner (half fan case, motor, fan, panel) and place on a bench or clean floor area. (l) Remove the fan retaining bolt from the end of the motor shaft and carefully remove the fan taking care not to misplace the drive key. (m) Remove the motor by releasing the four retaining bolts at the rear of the main air shutter casting. (n) Re-assemble in reverse order, ensuring that the motor shaft is properly greased before the fan is fitted. Gas Valve Actuator -Removal/Replacement Removal of gas valve actuators must only be carried out by suitably qualified personnel. Full details of removal/replacement procedures for all standard actuators fitted by Dunphy Combustion are given in the 'Unibloc' section of this manual. NOTE: THE FAN AND BOSS MUST BE REMOVED COMPLETE AS A SINGLE UNIT UND ER NO CIRCUMSTANCES MUST THE June of 165 TD/TAD4 Manual Rev 4

81 9 Faults and fault finding Operating Instructions For TD/TAD4 Dual Fuel Burner 9.1 Ratiotronic 6000/6006 Faults relating to electronic modulation burners must refer to the Ratiotronic 6000 controller manual Section 9. June of 165 TD/TAD4 Manual Rev 4

82 10 Useful Information Operating Instructions For TD/TAD4 Dual Fuel Burner Common Conversion Tables To Convert Into Multiply by Bars kg/m x 10 4 Bars p.s.i Bars kg/cm Btu J Btu kg.cal Btu/hr kw x 10 4 Btu/lb MJ/Kg x 10-3 ºC. ºf. (Cº x 9/5) + 32 cm.hg. ft. of H cm.hg. p.s.i ft. metres gallons (US) litres gallons (Imperial) litres gallons (US) gallons (Imperial) Hp kw hp (boiler) kw Inches cm Inches of H 2 O mb J Btu 9.48 x 10-4 kg.cal. Btu kg/cm² p.s.i kw Btu/hr kw kg.cal/min Litres gallons (Imperial) Litres/minute gallons(imp.)/second x 10-3 Metres ft p.s.i. bars x 10-2 p.s.i. mbars 69 June of 165 TD/TAD4 Manual Rev 4

83 RECORD OF COMMISSIONING VALUES Operating Instructions For TD/TAD4 Dual Fuel Burner SITE: BURNER TYPE: BOILER TYPE: BOILER OUTPUT: DATE OF COMMISSIONING: FUEL: NOZZLE TYPE & SIZE ADDRESS: SERIAL NUMBER: SERIAL NUMBER: OPERATING TEMP/PRESS: ENGINEERS NAME: PUMPED RING MAIN/GRAVITY SUPPLY? OIL PUMP WIRING DIAGRAM NO Firing Rate Position Burner Output Low Fire High Fire 10 CO 2 CO O 2 NO X Nett Flue Gas Temperature ºC Smoke Number Ambient Temperature Efficiency Electronic Modulation Channel 1 - Fuel Channel 2 - Air Furnace Pressure Fan Pressure Pump Outlet Pressure bar Oil Return Pressure ( Spill ) bar Boiler Temperature ºC Boiler Pressure June of 165 TD/TAD4 Manual Rev 4

84 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

85 Operating Instructions For TD/TAD4 Dual Fuel Burner 11 Exploded Diagram & Spare Parts List 11.1 Modulating Oil Modulating Gas Setup June of 165 TD/TAD4 Manual Rev 4

86 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

87 ITEM QTY. DESCRIPTION DWG/PART No. Operating Instructions For TD/TAD4 Dual Fuel Burner 1 1 TD410 LOW NOx COMBUSTION HEAD ASSEMBLY TD LOW NOx COMBUSTION HEAD ASSEMBLY TD410 COMBUSTION HEAD ASSEMBLY TD COMBUSTION HEAD ASSEMBLY GA23554 GA23555 GA23556 GA T4 VANE CASTING GA T410 FAN IMPELLOR (WHITE) T415 FAN IMPELLOR (BLUE) T420 FAN IMPELLOR (BLACK GA8765 GA8764 GA T4 BODY (FAN HALF) GA EYEBOLT T4 16MM 58mm O/D x32mm I/D EYEBLT A 1 10B 1 TD KW FAN MOTOR TD415 11KW FAN MOTOR TD420 15KW FAN MOTOR ANODISE OUTER SHUTTER TD410, TD415 ANODISE OUTTER SHUTTER TD420 ANODISE INNER SHUTTER TD410, TD415 ANODISE INNER SHUTTER TD420 SILENCER FOR TD410, TD415 SILENCER FOR TD420 T410/415 SNORKEL SILENCER WITH CHAMFERED CORNERS T420 SNORKEL SILENCER WITH CHAMFERED CORNERS MOTORF01210 MOTORF01235 MOTORF01250 GA15127 GA17290 GA15125 GA17210 GA08891 GA08893 GA21875 GA C 1 SNORKEL SILENCER MESH GA SPACER FOR MOD PLATE GA ROD END BEARING BEAROS SERVO MOTOR LINKARM GA MOD PLATE GA ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT T4 CONTROL PANEL MOUNTING BRACKET GA ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE DOOR FOR 542 ELECTRICAL ENCLOSURE DOOR FOR 552 ELECTRICAL ENCLOSURE DOOR FOR 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA12409 GA10726 GA10722 GA SIDE ENTRY GASKET GA GAS TRAIN FLANGE 80 GA BUTTERFLY VALVE 80mm GA A 1 22B 1 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN65 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN80 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN100 T4 VGD40 SIDE ENTRY ASSEMBLY DN65 T4 VGD40 SIDE ENTRY ASSEMBLY DN80 T4 VGD40 SIDE ENTRY ASSEMBLY DN100 GA23518A GA23518B GA23518C GA23529A GA23529B GA23529C 23 1 MALE STUD COUPLING 10MM x 3/8" BSP COMPAD mm BUNDI TUBE BUNDIT PRESSURE SWITCH PRESWI INNER NYLON ROLLER GA5761A 27 1 OUTER NYLON ROLLER GA5761B 28 1 Z TYPE MOUNTING GASKET Y TYPE MOUNTING GASKET GA11741 GA QRA2 UV CELL WITH BRACKET June of 165 TD/TAD4 Manual Rev 4

88 Operating Instructions For TD/TAD4 Dual Fuel Burner 30 1 JACKING SCREW FASHEX OIL ELECTRODE IGELEC OIL TUBE SUPPORT SPIDER GA SPLIT ELECTRODE BUSH GA ART1400 BURNER GUN GA POSITIONAL ELBOW 10-4L 10mm COMPAD /4"BSP DOWTY 'BONDED' SEAL SEADOW /4" BSP YORKSHIRE FTG. BRASS PLUG YORFIT SWIVEL ELBOW 10mm MSE 10-4 L COMPAD TWIN PORT SANDWICH BLOCK (INSIDE) GA9178A 40 2 SANDWICH BLOCK INNER O-RING ORINGS SANDWICH BLOCK OUTER O-RING 0RINGS TWIN PORT SANDWICH BLOCK (OUTSIDE) GA9178B 43 1 MALE STUD COUPLING 10mm MMC 10-4 L COMPAD STANDPIPE ADAPTOR 10mm MSA 10-4 L COMPAD EQUAL TEES 10mm 10 L COMPAD MOTOR HANGER PLATE SPACER GA VARIOTRONIC OIL METERING VALVE ASSEMBLY GA /4" MINI BALL VALVE VALOIL M5 COPPER WASHER COPWAS PSI PRESSURE GUAGE PRESGA MALE STUD COUPLING 10mm X 3/8" MMC 10-6 L COMPAD /8"BSP DOWTY 'BONDED' SEAL SEADOW PRESSURE SWITCH ADAPTOR BANMAN /4" COPPER WASHER COPWAS SAUTER HIGH OIL PRESSURE SWITCH BAILEY HIGH OIL PRESSURE SWITCH PRESWI00570 PRESWI BRIDGE HANDLE CONTOL STANDPIPE ADAPTORS 10mm MSA 10-8 L COMAD /2"BSP DOWTY 'BONDED' SEAL SEADOW /2" LUCIFER OIL SOLENOID VALVE SOLOIL MALE STUD COUPLING 10mm x 1/2" MMC 10-8 L COMPAD /8" BSP BANJO BOLT #7 x 70 GA /2" BSP BANJO BOLT #4 x 72 GA MANIFOLD No. 4 WITH VALVE CLUSTER GA COPPER WASHER 3/8" COPWAS COPPER WASHER 1/2" COPWAS "BSP 'HEAVYWEIGHT' BARREL NIPPLE PIPNIP DH1-1-CLOCKWISE ROTATION DH1-2-CLOCKWISE ROTATION DH1-1-ANTI-CLOCKWISE ROTATION DH1-1-ANTI-CLOCKWISE PUMDUN01012 PUMDUN01010 PUMDUN01025 PUMDUN POSITIONAL ELBOW 3/4" x 1/2" CONELB OIL SOL VALVE LUCIFER 1/2" N/C SOLOIL OIL MANIFOLD No. 1 GA /2" BSP BANJO BOLT #3 x 54 GA MOUNTING BRACKET FOR VALVE CLUSTER FITTET TO DH-1 GA D.90 MOTOR BELL HOUSING GA PUMP COUPLING ASSEMBLY PUMZCP00665 June of 165 TD/TAD4 Manual Rev 4

89 Operating Instructions For TD/TAD4 Dual Fuel Burner kW 2 POLE PUMP MOTOR MOTPUM MOTOR HANGER BRACKET GA BERGER LAHR SERVO MOTOR SERVBLO VARIOTRONIC OIL VALVE MOUNTING BRACKET GA mm DIAMETER BUNDI TUBE GA23514A mm DIAMETER BUNDI TUBE GA23514B mm DIAMETER BUNDI TUBE GA23514C mm DIAMETER BUNDI TUBE GA23514D 83-10mm DIAMETER BUNDI TUBE BUNDIT SAUTER LOW OIL PRESSURE SWITCH BAILEY LOW OIL PRESSURE SWITCH PRESWI00400 PRESWI00705 June of 165 TD/TAD4 Manual Rev 4

90 Operating Instructions For TD/TAD4 Dual Fuel Burner 11.2 Modulating Oil Modulating Gas with DH2 Pump (TD420 Only) June of 165 TD/TAD4 Manual Rev 4

91 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

92 ITEM QTY. DESCRIPTION DWG/PART No. Operating Instructions For TD/TAD4 Dual Fuel Burner 1 1 TD LOW NOx COMBUSTION HEAD ASSEMBLY TD COMBUSTION HEAD ASSEMBLY GA23555 GA T4 VANE CASTING GA T410 FAN IMPELLOR (WHITE) T415 FAN IMPELLOR (BLUE) T420 FAN IMPELLOR (BLACK GA8765 GA8764 GA T4 BODY (FAN HALF) GA EYEBOLT T4 16MM 58mm O/D x32mm I/D EYEBLT TD420 15KW FAN MOTOR MOTORF ANODISE OUTER SHUTTER TD420 GA ANODISE INNER SHUTTER TD420 GA A 1 SILENCER FOR TD420 GA B 1 T420 SNORKEL SILENCER WITH CHAMFERED CORNERS GA C 1 SNORKEL SILENCER MESH GA SPACER FOR MOD PLATE GA ROD END BEARING BEAROS SERVO MOTOR LINKARM GA MOD PLATE GA ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE DOOR FOR 542 ELECTRICAL ENCLOSURE DOOR FOR 552 ELECTRICAL ENCLOSURE DOOR FOR 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA12409 GA10726 GA10722 GA SIDE ENTRY GASKET GA GAS TRAIN FLANGE 80 GA BUTTERFLY VALVE 80mm GA A 1 22B 1 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN65 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN80 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN100 T4 VGD40 SIDE ENTRY ASSEMBLY DN65 T4 VGD40 SIDE ENTRY ASSEMBLY DN80 T4 VGD40 SIDE ENTRY ASSEMBLY DN100 GA23518A GA23518B GA23518C GA23529A GA23529B GA23529C 23 1 MALE STUD COUPLING 10MM x 3/8" BSP COMPAD mm BUNDI TUBE BUNDIT PRESSURE SWITCH PRESWI INNER NYLON ROLLER GA5761A 27 1 OUTER NYLON ROLLER GA5761B 28 1 Y TYPE MOUNTING GASKET GA QRA2 UV CELL WITH BRACKET JACKING SCREW FASHEX BRIDGE HANDLE CONTOL BRIDGE HANDLE CONTOL FLAME PLATE GA IGNITION ELECTRODE IGELEC OIL TUBE SUPPORT SPIDER GA SHELL HEAD FOR OIL BURNERS GA8233A 37 1 ART1400 OIL BURNER GUN GA POSITIONAL ELBOW 10-4L COMPAD00550 June of 165 TD/TAD4 Manual Rev 4

93 /4"BSP DOWTY 'BONDED' SEAL SEADOW /4" BSP YORKSHIRE BRASS PLUG YORFIT SWIVEL ELBOW 10mm MSE 10-4 L COMPAD MALE STUD COUPLING 12mm MMC 12-4 L COMPAD MALE STUD COUPLING 12mm X 3/8" MMC 12-6 L COMPAD /8"BSP DOWTY 'BONDED' SEAL SEADOW VARIOTRONIC OIL METERING VALVE ASSEMBLY & PARTS LIST Operating Instructions For TD/TAD4 Dual Fuel Burner GA VARIOTRONIC OIL VALVE MOUNTING BRACKET GA BERGER LAHR SERVO MOTOR EQUAL TEES 12mm 12 L COMPAD /4" MINI BALL VALVE MBV 14S VALOIL M5 FLAT COPPER WASHER COPWAS PSI PRESSURE GUAGE PRESGA STANDPIPE ADAPTORS 12mm MSA 12-8 L COMAD /2"BSP DOWTY 'BONDED' SEAL SEADOW OIL SOL VALVE LUCIFER 1/2" N/C SOLOIL OIL MANIFOLD No. 1 GA /2" BSP BANJO BOLT #3 x 54 GA MALE STUD COUPLING 12mm x 1/2" MMC 12-8 L COMPAD SAUTER LOW OIL PRESSURE SWITCH BAILEY LOW OIL PRESSURE SWITCH PRESWI00400 PRESWI OIL SOL VALVE LUCIFER 1/2" N/C 230V SOLOIL /2" BSP BANJO BOLT #8 x 72 GA /4" BSP BANJO BOLT #9 x 72 GA MANIFOLD No. 6U WITH DH-2 VALVE CLUSTER GA REDUCING NIPPLE, 1"-3/4" PIPNIP COPPER WASHER 1/2" COPWAS COPPER WASHER 3/4" COPWAS DH2 PUMP SERIES PUMDUN02013 PUMDUN02014 PUMDUN02015 PUMDUN /4" BSP DOWTY SEAL SEADOW POSITIONAL ELBOW 1" x 3/4" CONELB MOUNTING FLANGE DH2 FUEL UNIT GA MOUNTING BRACKET FOR VALVE CLUSTER FITTET TO DH-2 GA D.90 MOTOR BELL HOUSING GA PUMP COUPLING PUMZCP kW 2 POLE PUMP MOTOR MOTPUM MOTOR HANGER BRACKET GA PRESSURE SWITCH ADAPTOR BANMAN /4" COPPER WASHER COPWAS SAUTER HIGH OIL PRESSURE SWITCH BAILEY HIGH OIL PRESSURE SWITCH PRESWI00570 PRESWI mm BUNDI TUBE GA23870A mm BUNDI TUBE GA23870B mm BUNDI TUBE GA23870C June of 165 TD/TAD4 Manual Rev 4

94 Operating Instructions For TD/TAD4 Dual Fuel Burner 11.3 High Low Oil High Low Gas Setup (TD410 Only) June of 165 TD/TAD4 Manual Rev 4

95 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

96 Operating Instructions For TD/TAD4 Dual Fuel Burner ITEM QTY. DESCRIPTION DWG/PART No. 1 1 TD410 LOW NOx COMBUSTION HEAD ASSEMBLY TD410 COMBUSTION HEAD ASSEMBLY GA23554 GA T4 VANE CASTING GA T410 FAN IMPELLOR (WHITE) T415 FAN IMPELLOR (BLUE) T420 FAN IMPELLOR (BLACK GA8765 GA8764 GA T4 BODY (FAN HALF) GA EYEBOLT T4 16MM 58mm O/D x32mm I/D EYEBLT TD KW FAN MOTOR MOTORF ANODISE OUTER SHUTTER TD410, TD415 GA ANODISE INNER SHUTTER TD410, TD415 GA A 1 SILENCER FOR TD410, TD415 GA08891 GA B 1 T410/415 SNORKEL SILENCER WITH CHAMFERED CORNERS GA C 1 SNORKEL SILENCER MESH GA SPACER FOR MOD PLATE GA ROD END BEARING BEAROS SERVO MOTOR LINKARM GA MOD PLATE GA ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT T6 CONTROL PANEL MOUNTING BRACKET GA ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA DOOR FOR 542 ELECTRICAL ENCLOSURE DOOR FOR 552 ELECTRICAL ENCLOSURE DOOR FOR 667 ELECTRICAL ENCLOSURE GA10726 GA10722 GA SIDE ENTRY GASKET GA GAS TRAIN FLANGE 80 GA T4 VGD40 SIDE ENTRY ASSEMBLY DN65 T4 VGD40 SIDE ENTRY ASSEMBLY DN80 T4 VGD40 SIDE ENTRY ASSEMBLY DN100 GA23524A GA23524B GA23524C 23 1 MALE STUD COUPLING 10MM x 1/4" BSP COMPAD mm BUNDI TUBE BUNDIT PRESSURE SWITCH PRESWI00246 June of 165 TD/TAD4 Manual Rev 4

97 Operating Instructions For TD/TAD4 Dual Fuel Burner 26 1 INNER NYLON ROLLER GA5761A 27 1 OUTER NYLON ROLLER GA5761B 28 1 MOUNTING GASKET GA OIL ELECTRODE IGELEC SPLIT ELECTRODE BUSH GA OIL TUBE SUPPORT SPIDER GA HIGH LOW OIL NOZZLE SEE PROD. SHEET 33 2 TWIN NOZZLE BLOCK GA /4"BSP DOWTY 'BONDED' SEAL SEADOW MALE STUD COUPLING 10mm MMC 10-4 L COMPAD SWIVEL ELBOW 10mm MSE 10-4 L COMPAD TWIN PORT SANDWICH BLOCK (INSIDE) GA9178A 38 2 SANDWICH BLOCK INNER O-RING ORINGS SANDWICH BLOCK OUTER O-RING 0RINGS TWIN PORT SANDWICH BLOCK (OUTSIDE) GA9178B /4" LUCIFER OIL SOLENOID VALVE SOLOIL STANDPIPE ADAPTOR 10mm MSA 10-4 L COMPAD /4" BSP OIL MANIFOLD BLOCK 4 PORT GA /4" MINI BALL VALVE VALOIL M5 COPPER WASHER COPWAS PSI PRESSURE GUAGE PRESGA MALE STUD COUPLING 10mm x 1/2" MMC 10-8 L COMPAD /2"BSP DOWTY 'BONDED' SEAL SEADOW /2" LUCIFER OIL SOLENOID VALVE SOLOIL MALE STUD COUPLING 10mm X 3/8" MMC 10-6 L COMPAD /8"BSP DOWTY 'BONDED' SEAL SEADOW POSITIONAL ELBOW 3/4" x 1/2" CONELB DH1-1-CLOCKWISE ROTATION DH1-2-CLOCKWISE ROTATION DH1-1-ANTI-CLOCKWISE ROTATION DH1-1-ANTI-CLOCKWISE PUMDUN01012 PUMDUN01010 PUMDUN01025 PUMDUN COPPER WASHER 1/2" COPWAS COPPER WASHER 3/8" COPWAS MANIFOLD No. 4 WITH VALVE CLUSTER GA "BSP 'HEAVYWEIGHT' BARREL NIPPLE PIPNIP /2" BSP YORKSHIRE FITTING YORFIT /8" BSP BANJO BOLT #7 x 70 GA /2" BSP BANJO BOLT #4 x 72 GA D.90 MOTOR BELL HOUSING GA05900 June of 165 TD/TAD4 Manual Rev 4

98 Operating Instructions For TD/TAD4 Dual Fuel Burner 71 2 PUMP COUPLING PUMZCP PUMP COUPLING INSERT PUMZCP kW 2 POLE PUMP MOTOR MOTPUM MOTOR HANGER BRACKET GA MOTOR HANGER BRACKET SPACER GA BRIDGE HANDLE CONTOL mm BUNDI TUBE GA23517A mm BUNDI TUBE GA23517B mm BUNDI TUBE GA23517C mm BUNDI TUBE GA23517D mm BUNDI TUBE BUNDIT00115 June of 165 TD/TAD4 Manual Rev 4

99 Operating Instructions For TD/TAD4 Dual Fuel Burner 11.3 Modulating Gas High Low Oil Setup (TD410 Only) June of 165 TD/TAD4 Manual Rev 4

100 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

101 Operating Instructions For TD/TAD4 Dual Fuel Burner ITEM QTY. DESCRIPTION DWG/PART No. 1 1 TD410 LOW NOx COMBUSTION HEAD ASSEMBLY TD LOW NOx COMBUSTION HEAD ASSEMBLY TD410 COMBUSTION HEAD ASSEMBLY TD COMBUSTION HEAD ASSEMBLY GA23554 GA23555 GA23556 GA T4 VANE CASTING GA T410 FAN IMPELLOR (WHITE) GA T4 BODY (FAN HALF) GA EYEBOLT T4 16MM 58mm O/D x32mm I/D EYEBLT TD KW FAN MOTOR TD415 11KW FAN MOTOR TD420 15KW FAN MOTOR MOTORF01210 MOTORF01235 MOTORF ANODISE OUTER SHUTTER TD410, TD415 GA ANODISE INNER SHUTTER TD410, TD415 GA A 1 SILENCER FOR TD410, TD415 GA B 1 T410/415 SNORKEL SILENCER WITH CHAMFERED CORNERS GA C 1 SNORKEL SILENCER MESH GA SPACER FOR MOD PLATE GA ROD END BEARING BEAROS SERVO MOTOR LINKARM GA MOD PLATE GA ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT T4 CONTROL PANEL MOUNTING PLATE GA ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA DOOR FOR 542 ELECTRICAL ENCLOSURE DOOR FOR 552 ELECTRICAL ENCLOSURE DOOR FOR 667 ELECTRICAL ENCLOSURE GA10726 GA10722 GA SIDE ENTRY GASKET GA GAS TRAIN FLANGE 80 GA BUTTERFLY VALVE 80mm GA T4 VGD40 SIDE ENTRY ASSEMBLY DN65 T4 VGD40 SIDE ENTRY ASSEMBLY DN80 T4 VGD40 SIDE ENTRY ASSEMBLY DN100 GA23524A GA23524B GA23524C 23 1 MALE STUD COUPLING 10MM x 1/4" BSP COMPAD mm BUNDI TUBE BUNDIT PRESSURE SWITCH PRESWI INNER NYLON ROLLER GA5761A 27 1 OUTER NYLON ROLLER GA5761B 28 1 MOUNTING GASKET GA11741 June of 165 TD/TAD4 Manual Rev 4

102 Operating Instructions For TD/TAD4 Dual Fuel Burner 29 2 OIL ELECTRODE IGELEC SPLIT ELECTRODE BUSH GA OIL TUBE SUPPORT SPIDER GA HIGH LOW OIL NOZZLE SEE PROD. SHEET 33 2 TWIN NOZZLE BLOCK GA /4"BSP DOWTY 'BONDED' SEAL SEADOW MALE STUD COUPLING 10mm MMC 10-4 L COMPAD SWIVEL ELBOW 10mm MSE 10-4 L COMPAD TWIN PORT SANDWICH BLOCK (INSIDE) GA9178A 38 2 SANDWICH BLOCK INNER O-RING ORINGS SANDWICH BLOCK OUTER O-RING 0RINGS TWIN PORT SANDWICH BLOCK (OUTSIDE) GA9178B /4" LUCIFER OIL SOLENOID VALVE SOLOIL STANDPIPE ADAPTOR 10mm MSA 10-4 L COMPAD /4" BSP OIL MANIFOLD BLOCK 4 PORT GA /4" MINI BALL VALVE VALOIL M5 COPPER WASHER COPWAS PSI PRESSURE GUAGE PRESGA MALE STUD COUPLING 10mm x 1/2" MMC 10-8 L COMPAD /2"BSP DOWTY 'BONDED' SEAL SEADOW /2" LUCIFER OIL SOLENOID VALVE SOLOIL MALE STUD COUPLING 10mm X 3/8" MMC 10-6 L COMPAD /8"BSP DOWTY 'BONDED' SEAL SEADOW POSITIONAL ELBOW 3/4" x 1/2" CONELB DH1-1-CLOCKWISE ROTATION DH1-2-CLOCKWISE ROTATION DH1-1-ANTI-CLOCKWISE ROTATION DH1-1-ANTI-CLOCKWISE PUMDUN01012 PUMDUN01010 PUMDUN01025 PUMDUN COPPER WASHER 1/2" COPWAS COPPER WASHER 3/8" COPWAS MANIFOLD No. 4 WITH VALVE CLUSTER GA "BSP 'HEAVYWEIGHT' BARREL NIPPLE PIPNIP /2" BSP YORKSHIRE FITTING YORFIT /8" BSP BANJO BOLT #7 x 70 GA /2" BSP BANJO BOLT #4 x 72 GA D.90 MOTOR BELL HOUSING GA PUMP COUPLING PUMZCP PUMP COUPLING INSERT PUMZCP kW 2 POLE PUMP MOTOR MOTPUM00120 June of 165 TD/TAD4 Manual Rev 4

103 Operating Instructions For TD/TAD4 Dual Fuel Burner 74 1 MOTOR HANGER BRACKET GA MOTOR HANGER BRACKET SPACER GA BRIDGE HANDLE CONTOL mm BUNDI TUBE GA23517A mm BUNDI TUBE GA23517B mm BUNDI TUBE GA23517C mm BUNDI TUBE GA23517D mm BUNDI TUBE BUNDIT00115 June of 165 TD/TAD4 Manual Rev 4

104 Operating Instructions For TD/TAD4 Dual Fuel Burner 11.4 Multi-Oil Multi-Gas Exploded Diagram June of 165 TD/TAD4 Manual Rev 4

105 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

106 ITEM QTY. DESCRIPTION Operating Instructions For TD/TAD4 Dual Fuel Burner TD410 TD415 TD420 PART No. PART No. PART No. 1 1 T4 HINGE CASTING GA8714 GA8714 GA T4 VANE CASTING GA8715 GA8715 GA T4 IMPELLOR GA8765 GA8764 GA T4 FAN MOTOR MOTORF01210 MOTORF01230 MOTORF T4 PLAIN CASTING GA8716 GA8716 GA T4 INNER SHUTTER GA15126 GA15126 GA T4 OUTER SHUTTER GA15127 GA15127 GA A 1 T4 SILENCER GA8891 GA8891 GA8892 8B 1 T4 CHAMFERED SNORKEL SILENCER GA21875 GA21875 GA MOD PLATE SPACER GA7961 GA7961 GA T4 MOD PLATE GA17188 GA17188 GA RATIOTRONIC 6027 SERVO MOTOR ETCRAT00745 ETCRAT00745 ETCRAT CABINET HANGER PLATE GA9093 GA9093 GA CP552 UNIVERSAL HANDED BURNER CABINET GA19714 GA19714 GA CP552 CABINET DOOR GA10722 GA10722 GA /4" x 10mm SWIVEL ELBOW COMPAD00505 COMPAD00505 COMPAD n10mm BUNDI TUBE BUNDIT00090 BUNDIT00090 BUNDIT /4" BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD00485 COMPAD LGW50 A2P PRESSURE SWITCH PRESWI00245 PRESWI00245 PRESWI DN80 GASKET GASKET00970 GASKET00970 GASKET QRA2 UV CELL AND BRACKET FAN HUB FOR T4 BURNER GA8767 GA8767 GA T4 BOILER MOUNTING GASKET GA11741 GA11742 GA T4 MULTI-FLAME MOUNTING SECTION GA20040 GA20134 GA T MULTI-FLAME MOUNTING SECTION NOSE CONE GA20042 GA20135 GA T4 AIR GUIDE VANE (WHEN FITTED) GA22534 GA22534 GA T4 MULTI-FLAME SPLIT BLOCK GA19506B GA19506B GA19506B /8" BSP DOWTY SEAL SEADOW00050 SEADOW00050 SEADOW /8" BSP x 6mm MALE STUD COUPLING COMPAD00105 COMPAD00105 COMPAD n6mm BUNDI TUBE BUNDIT00070 BUNDIT00070 BUNDIT /8" BSP NON - RETURN VALVE VALVCH00220 VALVCH00220 VALVCH /8" BSP x 6mm STANDPIPE ADAPTOR COMPAD00280 COMPAD00280 COMPAD ART106 BURNER GUN NOZZLE BLOCK ASSEMBLY - OUTER NOZZLE GA20137 GA20137 GA T4 MULTI-PIPE HEAD GA22262 GA20136 GA M5 FLAT COPPER WASHER COPWAS00025 COPWAS00025 COPWAS OIL SHELL HEAD FOR MULTI-OIL DUAL FUEL BURNERS GA22263 GA18784 GA TD4 MULTI-OIL MULTI-GAS FLAMEPLATE GA22662 GA22196 GA ELECTRODE SPLIT BUSH GA8264 GA8264 GA GAS IGNITION ELECTRODES IGELEC00100 IGELEC00100 IGELEC ORING, BS206 VITON ORINGS00180 ORINGS00180 ORINGS ORING VITON ORINGS01025 ORINGS01025 ORINGS T3-T5 OIL BURNER SANDWICH BLOCK - PART A T3-T5 OIL BURNER SANDWICH BLOCK - PART B GA9178A GA9178A GA9178A GA9178B GA9178B GA9178B /4" BSP x 6mm MALE STUD COUPLING COMPAD00620 COMPAD00620 COMPAD MOD PLATE SPACERS GA7961 GA7961 GA7961 June of 165 TD/TAD4 Manual Rev 4

107 Operating Instructions For TD/TAD4 Dual Fuel Burner 45 1 PUMP MOTOR MOUNTING BRACKET GA9562 GA9562 GA PUMP MOTOR MOTPUM00220 MOTPUM00220 MOTPUM PUMP MOTOR HOUSING GA5900 GA5900 GA DH PUMP VALVE BRACKET GA10190 GA10190 GA DH OIL PUMP SERIES PUMDUN01021 PUMDUN01021 PUMDUN No.3 BANJO BOLT GA10125 GA10125 GA No.1 BANJO MANIFOLD BLOCK GA16777 GA16777 GA /2" BSP DOWTY SEAL SEADOW00110 SEADOW00110 SEADOW /2" BSP N/C LUCIFER OIL VALVE SOLOIL00240 SOLOIL00240 SOLOIL /2" BSP x 10mm MALE STUD COUPLING - - COMPAD /4" BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD /4" BSP YORKSHIRE FITTING YORFIT00510 YORFIT00510 YORFIT MANIFOLD BANJO BLOCK GA16780 GA16780 GA MANIFOLD BANJO BOLT A GA10382 GA10382 GA MANIFOLD BANJO BOLT B GA10143 GA10143 GA /2" BSP x 10mm STANDPIPE ADAPTOR COMPAD00520 COMPAD00520 COMPAD /8" BSP x 10mm MALE STUD COUPLING COMPAD00490 COMPAD00490 COMPAD /8" BSP DOWTY SEAL SEADOW00100 SEADOW00100 SEADOW /2" BSP SRV OIL SOLENOID VALVE SOLOIL00360 SOLOIL00360 SOLOIL mm EQUAL TEE PIECE COMPAD00520 COMPAD00520 COMPAD mm EQUAL ELBOW COMPAD00435 COMPAD00435 COMPAD VT2 METERING VALVE ASSEMBLY GA16090 GA16090 GA RATIOTRONIC 6026 SERVO MOTOR ETCRAT00720 ETCRAT00720 ETCRAT TWIN VT2 METERING VALVE MOUNTING BRACKET OILMET00753 OILMET00753 OILMET /4" BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD00485 COMPAD /4" BSP DOWTY SEAL SEADOW00105 SEADOW00105 SEADOW /4" BSP x 10mm STANDPIPE ADAPTOR COMPAD00535 COMPAD00535 COMPAD /4" BSP MINI OIL BALL VALVE VALOIL00110 VALOIL00110 VALOIL BAR (0-600 PSI) PRESSURE GAUGE PRESGA00155 PRESGA00155 PRESGA PRESSURE SWITCH ADAPTOR (1/4" BSP - 1/2" BSP REDUCER) HIGH OIL PRESSURE SWITCH (SAUTER) HIGH OIL PRESSURE SWITCH (BAILEY) BANMAN00170 BANMAN00170 BANMAN00170 PRESWI00570 PRESWI00700 PRESWI00570 PRESWI00700 PRESWI00570 PRESWI /8" BSP x 10mm STANDPIPE ADAPTOR COMPAD00540 COMPAD00540 COMPAD DH OIL PUMP MOUNTING FLANGE - - PUMFLA /4" BSP DOWTY SEAL SEADOW00120 SEADOW00120 SEADOW /4" BSP x 1" BSP REDUCING NIPPLE - - PIPNIP /2" BSP x 3/4" BSP REDUCING NIPPLE PIPNIP01430 PIPNIP /4" BSP x 1" BSP POSITIONABLE ELBOW - - CONELB /2" BSP x 3/4" BSP POSITIONABLE ELBOW CONELB00125 CONELB /2" COPPER WASHER COPWAS00110 COPWAS00110 COPWAS /4" COPPER WASHER COPWAS00115 COPWAS00115 COPWAS NYLON ROLLER GA5761A GA5761A GA5761A 83 3 STEEL BUSH FOR NYLON ROLLER GA5761B GA5761B GA5761B 84 1 BRIDGE HANDLE CONTOL02285 CONTOL02285 CONTOL PUMP COUPLING & INSERT ASSEMBLY (CHALLENGE) PUMZCP00665 PUMZCP00665 PUMZCP COVER PLATE FOR PUMP HOUSING GA6707 GA6707 GA mm DIAMETER BUNDI TUBE GA23697A GA23697A GA23697A mm DIAMETER BUNDI TUBE GA23697B GA23697B GA23697B June of 165 TD/TAD4 Manual Rev 4

108 Operating Instructions For TD/TAD4 Dual Fuel Burner mm DIAMETER BUNDI TUBE GA23697C GA23697C GA23697C mm DIAMETER BUNDI TUBE GA23697D GA23697D GA23697D mm EYEBOLT EYEBLT00100 EYEBLT00100 EYEBLT /4" COPPER WASHER COPWAS00075 COPWAS00075 COPWAS SWIVEL RUN TEE COMPAD00655 COMPAD00655 COMPAD LOW OIL PRESSURE SWITCH (SAUTER)LOW OIL PRESSURE SWITCH (BAILEY) PRESWI00400 PRESWI00705 PRESWI00400 PRESWI00705 PRESWI00400 PRESWI T4 GAS SIDE ENTRY PLATE PLCSIDENT00120 PLCSIDENT00120 PLCSIDENT A 1 DN80 BUTTERFLY VALVE WITH BERGER LAHR SERVO MOTOR T4 DN65 UNIBLOC ASSEMBLY T4 DN80 UNIBLOC ASSEMBLY T4 DN100 UNIBLOC ASSEMBLY GA17187 GA17187 GA17187 GA23518A GA23518B GA23518C GA23518A GA23518B GA23518C GA23518A GA23518B GA23518C 97B 1 T4 DN65 VG4.40 ASSEMBLY T4 DN80 VG4.40 ASSEMBLY T4 DN100 VG4.40 ASSEMBLY GA23529A GA23529B GA23529C GA23529A GA23529B GA23529C GA23529A GA23529B GA23529C 98 1 ART106 NOZZLE BLOCK HOLDER GA09150A GA09150A GA09150A 99 1 TWIN OIL IGNITION ELECTRODE IGELEC00130 IGELEC00130 IGELEC T4 MULTI-PIPE HEAD GA22262 GA20136 GA T4 MULTI-PIPE GAS NOZZLE GA23522 GA23522 GA DOUBLE BLOCK ELECTRODE HOLDER GA11883 GA11883 GA11883 June of 165 TD/TAD4 Manual Rev 4

109 11.5 TD410 Low NOx Combustion Head Assembly Operating Instructions For TD/TAD4 Dual Fuel Burner 11.6 TD Low NOx Combustion Head Assembly June of 165 TD/TAD4 Manual Rev 4

110 Operating Instructions For TD/TAD4 Dual Fuel Burner 11.7 TD410 Combustion Head Assembly 11.8 TD Combustion Head Assembly June of 165 TD/TAD4 Manual Rev 4

111 11.9 DN65 Unibloc Operating Instructions For TD/TAD4 Dual Fuel Burner DN80 Unibloc DN100 Unibloc June of 165 TD/TAD4 Manual Rev 4

112 Operating Instructions For TD/TAD4 Dual Fuel Burner VGD40.65 Assembly for Pneumatic Modulating and High Low Burners VGD40.80 Assembly for Pneumatic Modulating and High Low Burners June of 165 TD/TAD4 Manual Rev 4

113 Operating Instructions For TD/TAD4 Dual Fuel Burner VGD Assembly for Pneumatic Modulating and High Low Burners VGD40.65 Assembly for Electronic Modulating Burners June of 165 TD/TAD4 Manual Rev 4

114 11.16 VGD40.80 Assembly for Electronic Modulating Burners Operating Instructions For TD/TAD4 Dual Fuel Burner VGD Assembly for Electronic Modulating Burners June of 165 TD/TAD4 Manual Rev 4

115 Operating Instructions For TD/TAD4 Dual Fuel Burner 12 Component Information 12.1 LFL1.333 Burner Control Box To avoid injury to persons, damage to property or the environment, the following warning notes should be observed! Do not open, interfere with or modify the unit! Before performing any wiring changes in the connection area of the LFL1, completely isolate the unit from the mains supply (all-polar disconnection) Ensure protection against electric shock hazard by providing adequate protection for the burner control s connection terminals Check to ensure that wiring is in an orderly state and that the wires are firmly connected (refer to «Commissioning notes») Press the lockout reset button only manually (applying a force of no more than 10 N), without using any tools or pointed objects. Do not press the lockout reset button on the unit or the remote lockout reset button for more than 10 seconds since this damages the lockout relay in the unit Fall or shock can adversely affect the safety functions. Such units may not be put into operation, even if they do not exhibit any damage. In the case of flame supervision with UV detectors QRA..., it should be noted that sources of radiation such as halogen lamps, welding equipment, special lamps, ignition sparks, as well as X-rays and gamma radiation, can produce erroneous flame signals. Mounting notes Ensure that the relevant national safety regulations are observed. When using 2 UV detectors QRA..., make certain that the detectors cannot see one another Installation notes Installation work must be carried out by qualified staff. Always run the high-voltage ignition cables separately while observing the greatest possible distance to the unit and to other cables. Do not mix up live and neutral conductors Electrical connection of ionization probe and flame detector It is important to achieve practically disturbance and loss-free signal transmission: Never run the detector cable together with other cables. Line capacitance reduces the magnitude of the flame signal. Use a separate cable of low capacitance Observe the maximum permissible detector cable lengths (refer to «Technical data») 2 UV detectors QRA... can be connected in parallel. The ionization probe is not protected against electric shock hazard. Locate the ignition electrode and ionization probe such that the ignition spark cannot arc over to the ionization probe (risk of electrical overloads). In connection with the QRA..., earthing of terminal 22 is mandatory. Supervision with both ionization probe and UV detector QRA... is possible, but for safety reasons with the exception of the second safety time «t9» only one flame detector may be active at a time. At the end of the second safety time, one of the detectors must be inactive, however, that is, the detected flame must have extinguished, e.g. by switching off the ignition valve at terminal 17. June of 165 TD/TAD4 Manual Rev 4

116 Flame supervision with ionisation probe Operating Instructions For TD/TAD4 Dual Fuel Burner Voltage at the ionization probe: Operation: AC 330 V ±10 % Test: AC 380 V ±10 % Short-circuit current max: 0.5 ma Required ionization current min: 6 µa Recommended range of measuring instrument: µa Perm. length of detector cable: Normal cable, laid separately. (multicore cable not allowed) max. 80 m Shielded cable: max. 140 m (e.g. high-frequency cable, shield connected to terminal 22 Flame supervision with QRA Supply voltage: Operation: AC 330 V ±10 % Test: AC 380 V ±10 % Required detector current min: 70 µa Possible detector current: Operation: max. 680 µa Test: max µa ¹) Perm. length of detector cable: Normal cable, laid separately (Multicore cable not permitted): max. 100m Shielded cable: max. 200 m (e.g. high-frequency cable, shield connected to terminal 22) Note1) During the pre-purge time with higher test voltage: self-ignition and extraneous light test June of 165 TD/TAD4 Manual Rev 4

117 Operating Instructions For TD/TAD4 Dual Fuel Burner LFL Technical Data June of 165 TD/TAD4 Manual Rev 4

118 Operating Instructions For TD/TAD4 Dual Fuel Burner LFL Characteristics Mains voltage AC 230 V 15 / +10 % AC 100 V 15 %...AC 110 V +10 % Mains frequency Hz ±6 % Unit fuse (built-in) T6,3H250V to DIN EN Primary fuse (external) Power consumption Perm. input current at terminal 1 max. 10 A (slow) approx. AC 3,5 VA max. 5 A continuously, peaks up to 20 A for 20 ms Perm. load on control terminals 3, 6, 7, , max. 4 A continuously, peaks up to 20 A for max. 20 ms, total max. 5 A Required switching capacity of switching devices 1 A, AC 250 V - Between terminals 4 and 5 1 A, AC 250 V - Between terminals 4 and 12 min. 1 A, AC 250 V - Between terminals 4 and 14 depending on the load on terminals LFL Operation June of 165 TD/TAD4 Manual Rev 4

119 General Operating Instructions For TD/TAD4 Dual Fuel Burner Detector and extraneous light test are resumed immediately on completion afterburn time «t13». Fuel valves that are not closed, or not fully closed, immediately initiate lockout on completion of the afterburn time «t13». The test terminated when the prepurge time «t1» of the next startup sequence. The proper functioning of the flame supervision circuit is automatically during each startup phase of the burner During the postpurge time «t6», the control contacts for the release checked to ensure they have not welded. The built-in unit fuse protects the control contacts against overloads. Preconditions for start up Burner control must be reset Sequence switch must be in its start position - voltage at terminals 4 and 11 present and air damper closed End switch «z» for the CLOSED position must feed voltage from terminal 11 to terminal 8 The contacts of control thermostat or pressurestat «W» and other contacts of switching devices connected between terminal 12 and «LP» must be closed _ e.g. control contact for the oil preheater s temperature. Terminal 4 must be live The N.C. contact of the air pressure switch must be closed - «LP» test Start up sequence A A-B B B-C C C-D A Start command (delivered by «R» for instance) Startup sequence Operating position of the burner Burner operation (according to the control commands delivered by «R») Controlled shutdown via «R» Sequence switch travels to start position «A», postpurging During burner off periods, only control outputs 11 and 12 carry voltage and the air damper is in its CLOSED position as defined by end switch «z» of the actuator. Also, in order to perform the detector and extraneous light test, the flame supervision circuit is live (terminals 22 / 23 and 22 / 24). Start command delivered by «R» «R» closes the start control loop between terminals 4 and 5 - The sequence switch starts running - Only prepurging, power is immediately fed to the fan motor connected to terminal 6 - Pre and postpurging; on completion of «t7», power is fed to the fan motor or flue gas fan connected to terminal 7 - On completion of «t16», the control command to open the air damper is delivered via terminal 9 - No power is fed to terminal 8 during the positioning time - The sequence switch continues its travel only after the air damper has fully opened. t1 Prepurge time with air damper fully open - During «t1», the correct functioning of the flame supervision circuit is tested - If test is not successful, the burner control will initiate lockout June of 165 TD/TAD4 Manual Rev 4

120 Operating Instructions For TD/TAD4 Dual Fuel Burner Shortly after the start of «t1», the air pressure switch must change over from terminal 13 to terminal Otherwise lockout - Start of air pressure check At the same time, terminal 14 must be live since the ignition transformer will be powered and the fuel released via this current path. On completion of the prepurge time, the burner control will drive the air damper to the low-fire position via terminal 10, which is determined by the changeover point of auxiliary switch «m». During the positioning time, the sequence switch stops again. A short time later, the motor of the sequence switch will be switched to the control section of the burner control. This means that, from now on, positioning signals delivered to terminal 8 have no impact on the burner s further startup sequence (and on subsequent burner operation): t5 Interval - On completion of «t5», power is fed to terminal 20; at the same time, control outputs and input 8 are galvanically separated from the unit s control section. - The LFL1... is now protected against return voltages from the power control loop. - The startup sequence of the LFL1 ends with the release of «LR» at terminal 20 - After a number of idle steps (steps with no change of the contact position), the sequence switch switches itself off Expanding flame burners TSA t3 t4 Ignition safety time On completion of «TSA», a flame signal must be present at terminal 22. It must not be interrupted until controlled shutdown takes place - otherwise lockout Pre-ignition time Release of fuel via terminal 18 Interval «BV1 BV2» or «BV1 - LR» - On completion of «t4», terminal 19 is live - That powers «BV2» connected to the actuator s auxiliary switch «v» Control sequence under fault conditions and lockout indication In the event of any kind of fault, the sequence switch will stop and, with it, the lockout indicator. The symbol above the indicator s reading mark gives the type of fault: June of 165 TD/TAD4 Manual Rev 4

121 Operating Instructions For TD/TAD4 Dual Fuel Burner If lockout occurs, the burner control can immediately be reset: - Do not press the lockout reset button for more than 10 seconds The sequence switch always returns to its start position first - After resetting - After correction of a fault which resulted in plant shutdown - After each power failure During that period of time, power is only fed to terminals 7 and Then, the LFL1... begins with a new burner startup sequence. June of 165 TD/TAD4 Manual Rev 4

122 LFL Glossary of symbols Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

123 12.2 RWF 40 Burner temperature controller Operating Instructions For TD/TAD4 Dual Fuel Burner The RWF40 is used to control the boiler temperature. It is configured to modulate the burner up and down when firing on gas and provide high/low thermostat functions when firing on oil. In modulating operation the RWF40 operates as a PID controller. In 2- stage operation the RWF40 provides control based on the set switching threshold. The setpoint of the RWF40 can be adjusted either on the controller itself or externally. June of 165 TD/TAD4 Manual Rev 4

124 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

125 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

126 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

127 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

128 12.3 Unibloc Operating Instructions For TD/TAD4 Dual Fuel Burner Unibloc General Arrangements All Unibloc gas trains are manufactured and tested in accordance with EN 161 : 1991 'Automatic Shut-off Valves for Gas Burners and Gas Appliances' The Unibloc body is cast iron to BS 1452 grade 220 (the 100 N.B. body conforming to EN161 is S.G. cast iron to BS 2789 grade 2712). All bodies are manufactured in one piece and are precision machined to accept the various gas valve actuators that are described in section 2. The standard unit is designed for use with 2nd and 3rd family gases and is fitted with plated carbon steel valve seating rings. For other gas applications, e.g. bio or producer gas, the valve seating rings are manufactured out of grade 321 stainless steel, because of the corrosive nature of these gases. Where hydrogen sulphide (H2 S) is present in the gas advice must be sought from Dunphy Technical Department. A gas filter is fitted around the seating of the first stage valve to prevent foreign bodies entering the Unibloc and causing valve seating problems. Gas filters are available to suit the various specifications as required. June of 165 TD/TAD4 Manual Rev 4

129 Operating Instructions For TD/TAD4 Dual Fuel Burner Valve actuators are supplied as standard with plated carbon steel seat assemblies fitted with nitrile rubber seating discs. If valves are required to be used on bio, producer or other corrosive gases, the valve seat assemblies will be manufactured in 321 stainless steel with viton seating discs. Installation Select a location where the ambient temperature will be within the range of 0 C to +50 C, ensure that the gas supply pipework is clean and contains no loose particles, fit valve to pipework so that the gas flow travels in the direction of the arrows on the valve casing. Please note that the 40, 50, 65, 80 and 100 mm N.B. valve bodies should be mounted with the inlet flange facing vertically downwards. The 125 mm. N.B. valve body has an adjustable inlet flange section that can be rotated to face in various directions Due to the size and weight of the 100mm N.B. Unibloc, it is recommended that after installation in the gas pipework the valve body is supported using the hole drilled in the valve body rib. June of 165 TD/TAD4 Manual Rev 4

130 Operating Instructions For TD/TAD4 Dual Fuel Burner mm Ratiotronic Unibloc exploded diagram and parts list. June of 165 TD/TAD4 Manual Rev 4

131 Operating Instructions For TD/TAD4 Dual Fuel Burner mm Ratiotronic Unibloc with pilot exploded diagrams and parts list June of 165 TD/TAD4 Manual Rev 4

132 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

133 Operating Instructions For TD/TAD4 Dual Fuel Burner mm Ratiotronic Unibloc exploded diagrams and parts list June of 165 TD/TAD4 Manual Rev 4

134 Operating Instructions For TD/TAD4 Dual Fuel Burner mm Ratiotronic Unibloc with pilot exploded diagrams and parts list June of 165 TD/TAD4 Manual Rev 4

135 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

136 Operating Instructions For TD/TAD4 Dual Fuel Burner mm Ratiotronic Unibloc exploded diagrams and parts list June of 165 TD/TAD4 Manual Rev 4

137 Operating Instructions For TD/TAD4 Dual Fuel Burner mm Ratiotronic Unibloc with pilot exploded diagrams and parts list June of 165 TD/TAD4 Manual Rev 4

138 June of 165 TD/TAD4 Manual Rev 4 Operating Instructions For TD/TAD4 Dual Fuel Burner

139 12.4 Butterfly Gas Valve Operating Instructions For TD/TAD4 Dual Fuel Burner General Arrangement June of 165 TD/TAD4 Manual Rev 4

140 Exploded Diagram Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

141 12.5 Siemens VGD20 and VGD40 Gas Valve Blocks Operating Instructions For TD/TAD4 Dual Fuel Burner Double gas valves for use on gas trains, consisting of 2 class «A» safety shutoff valves. Suited for use in connection with gases of the gas families I...III. The double gas valve is to be combined with 2 actuators of the SKP series (e.g. to provide the functions of 2 safety shutoff valves connected in series, with different types of gas pressure governor if required). Supplementary data sheets on the actuators is located at the end of this section. To avoid injury to persons, damage to property or the environment, the following warning notes should be observed! VGD20 Do not open, interfere with or modify the double gas valve, except when fitting the service replacement set! _ When used in connection with gas, the valves constitute part of the entire safety system. Fall or shock can adversely affect the safety functions. Such valves may not be put into operation, even if they do not exhibit any damage. VGD40 Protect the actuator against excessive temperatures (caused by radiation, for example), to ensure the maximum permissible ambient temperatures will not be exceeded. Mounting notes Ensure that the relevant national safety regulations are complied with. To mount the double gas valve VGD20..., 2 flanges type AGA41... / AGA51... are required. To prevent cuttings from falling inside the valve, first mount the flanges to the piping and then clean the associated parts. On the gas train, the valve can be mounted in any position, but the permissible mounting positions of the associated actuator must be observed (refer to the relevant Data Sheet) The direction of gas flow must be in accordance with the arrow on the valve body. When used in combination with the SKP10..., SKP15..., SKP25... or SKP75..., the minimum gas pressure switch must always be mounted upstream of the double gas valve! The electro hydraulic SKP15... actuator, which is used for shutoff functions, must always be mounted on the inlet side while the actuators with integrated governor (SKP25..., SKP75...,) must always be fitted on the outlet side of the valve (with a contoured disk). Check to ensure the bolts on the flanges are properly tightened. Check to ensure the connections with all components are tight. Mounting and replacement of the actuator can take place while the valve is under pressure. Sealing materials are not required. Ensure that the O-rings are fitted between the flanges and the valve body. Installation notes Installation work must be carried out by qualified staff. If the available gas pressure exceeds the valve s maximum permissible operating pressure, the gas pressure must be reduced by a pressure regulator upstream of the valve. June of 165 TD/TAD4 Manual Rev 4

142 Commissioning notes Operating Instructions For TD/TAD4 Dual Fuel Burner Commissioning work must be carried out by qualified staff. If environmental conditions produce corrosion (e.g. sea climate), apply protective coating. Check wiring carefully prior to commissioning. Standards CE conformity in accordance with the directives of the European Union - Directive for pressure equipment 97/23 EEC - Directive for gas appliances 90/396 EEC Service notes Check the correct functioning and the internal and external tightness of the VGD... each time a valve has been replaced. The valve may only be replaced by qualified staff. VGD20 The double gas valves VGD20... are of the normally closed type and have 2 disks, one noncontoured disk on the inlet side and one contoured disk on the outlet side. The stems are guided on both sides of the disks, thus ensuring precise alignment and tight shutoff. The high closing force of the return spring is supported by the prevailing gas pressure (class «A» to EN 161). A strainer on the inlet side protects the valve and downstream controls against dirt. Valve body and connecting flanges are made of die-cast aluminium, the seals of nitril rubber, and the stems of stainless steel. The double gas valves feature a pilot gas connection Rp¾". Gas valve, flanges and actuators are supplied as separate items. The 4 screws required to fit the SKP... to the valve are contained in the terminal compartment. No special tools are required for assembly. The connecting flanges have a test point. They are internally threaded and supplied as separate items, together with the necessary accessories, such as bolts, nuts, seals, etc. The overall flange dimensions and bore-holes are identical, so that all types of flanges can be fitted to the double gas valve, irrespective of nominal size. This means that a 1½" flange can be fitted to a 2" VGD... valve, and vice versa. Each double gas valve requires 2 connecting flanges, which are to be ordered as separate items. General Data Class A (EN 161) Group 2 (EN 161) Types of gases gas families I, II, III (to G260 of DVGW) air Built-in strainer, mesh size 0.9 mm Perm. medium temperature C Mounting spring housing horizontal or vertical, pointing downward Flanges for VGD40... to ISO 7005; PN16 Materials - VGD20... die-cast aluminium - VGD40... sand-cast aluminium June of 165 TD/TAD4 Manual Rev 4

143 VGD40 Operating Instructions For TD/TAD4 Dual Fuel Burner The double gas valves VGD40... are double seat disk valves of the normally closed type. The stems are guided on both sides of the disks, thus ensuring a precise stroke and tight shutoff. To improve the control performance, the disks at the bottom are pro-filed. The patented double seats are closed by 2 springs. The high closing force of the return spring is supported by the prevailing gas pressure (class «A» to EN 161). The spring of each stem exerts a pressure on the disk so that there is a defined closing force acting on each disk. The surface area proportions of the 2 valve disks per stem are such that the closing force increases as the inlet pressure increases (class «A» valve to EN 161). A strainer on the inlet side protects the valve and downstream controls against dirt. The 4 screws required to fit the SKP... to the valve are contained in the terminal compartment. The double gas valves DN correspond to the standard valve sizes of single valves (EN 558). The VGD40... are supplied with a pilot gas flange having a ¾ connection for the pilot gas line and a ¼ connection for an impulse line. This impulse line connection between the 2 valves and another impulse line connection on the outlet flange can be connected directly to the constant pressure governor SKP20... fitted to «V1» or «V2». A universal mounting plate facilitates attachment of a number of commercially available pressure switches or valves proving devices. Both the pilot gas flange and the universal mounting plate are exchangeable and can be fitted on either side of the valve. June of 165 TD/TAD4 Manual Rev 4

144 Power Output Curves Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

145 Siemens SKP actuators Operating Instructions For TD/TAD4 Dual Fuel Burner The combination of actuator and valve provides the following functions: - Safety shutoff valve (SKP15...) - Safety shutoff valve with gas pressure governor / controller (SKP25..., SKP55..., and SKP75...) The electrohydraulic SKP... actuators together with the valves are designed for use with gases of gas families I...III and air. They are used primarily on gas-fired combustion plant. The actuators open slowly and close rapidly. They can be combined with any of the above mentioned valve types and nominal sizes. The actuator can be supplied with end switch (for indicating the fully closed position). The SKP25... operates as a constant pressure governor with a setpoint spring. Its field of use are primarily forced draft gas burners - with mechanical fuel / air ratio control - with electronic fuel / air ratio control The SKP55... operates as a differential pressure governor. Its field of use are primarily - combustion plant with combined heat recovery systems - plant where pressure conditions in the burner and in the combustion chamber do not change in proportion to load changes - burners with adjustable fuel / air mixing devices in the burner head - plant with negative pressure levels on the gas or air side. The SKP75... operates as a ratio controller and provides control of the gas pressure depending on the pressure of the combustion air, ensuring that the gas / air ratio remains constant across the entire load range. Its field of use are primarily modulating forced draft gas burners. To prevent injury to persons, damage to property or the environment, the following warning notes should be observed! Do not open, interfere with or modify the actuators! June of 165 TD/TAD4 Manual Rev 4

146 Operating Instructions For TD/TAD4 Dual Fuel Burner All activities (mounting, installation and service work, etc.) must be performed by qualified staff Check to ensure that the impulse pipes are properly fitted and tight Fall or shock can adversely affect the safety functions. Such actuators must not be put into operation, even if they do not exhibit any damage. If mains voltage is fed to the end switch via the second plug-in space, protective earth must be connected to the actuator via the same plug. Use of connectors conforming to DIN EN A is mandatory The connectors used must have cable strain relief The pump s stem must not be pulled out using the overstroke element since that part could become loose. If the available gas pressure exceeds the maximum permissible operating pressure of the valve / SKP..., it must be lowered by an upstream pressure controller. The pressure switch for lack of gas must always be fitted upstream of the gas valve when used in connection with the SKP The inside diameter of the impulse pipes must be a minimum of 6 mm. The impulse pipes must be installed such that the differential pressure can be acquired with no disturbance (unfavourable flow conditions). Pressure test points must not protrude and be flush with the inside diameter of the pipe or duct wall. The impulse lines to the governor / controller should be as short as possible, enabling the governor / controller to respond quickly should sudden load changes occur. Installation of impulse pipes In the case of unsafe combustion chamber pressure pipes (e.g. resulting from potential leaks), the setting must also be checked during operation without having the combustion chamber pipe connected, especially with respect to maximum burner capacity. The impulse pipes must be fitted such that the differential pressure can be acquired with no disturbance. With gas / air ratios > 3, the June of 165 TD/TAD4 Manual Rev 4

147 Operating Instructions For TD/TAD4 Dual Fuel Burner impulse pipes for the combustion air and the combustion chamber pressure must have an inside diameter of at least 8 mm. The impulse pipe for the combustion chamber pressure must be fitted such that the gases will cool down in the vicinity of the impulse pipe and condensing gases cannot enter the controller but will return to the combustion chamber. Recommendations: The gas pressure should be acquired at a distance of 5 times the nominal pipe size downstream from the valve. Do not use the lateral test points on the VG... valve body for picking up the pressure Considering the combustion chamber pressure If the resistance value of the combustion chamber / heat exchanger / stack system is constant, the combustion chamber pressure changes in proportion to the gas and combustion air pressure as the burner s output changes. In that case, the combustion chamber pressure need not be fed to the SKP75... as a disturbance variable. However, if the combustion chamber pressure does not change to the same extent as the gas and air pressure as this is the case in plants with flue gas fan or modulating flue gas damper the combustion chamber pressure must be fed to the SKP75... as a disturbance variable, enabling the controller to counteract. Ensure that the relevant national safety regulations are complied with The quadratic arrangement of the fixing holes allows the actuator to be fitted in 4 different positions, each step being 90 The actuator can be mounted or replaced while the system is under pressure; sealing materials are not required Electrical commissioning may only be performed when the SKP is fitted to the valve; otherwise, the SKP can be damaged. Power is supplied and connection of the end switch is made directly via a connecting cable (conforming to DIN EN A) The end switch is factory set. When power is applied, the pump will be activated and the control valve closed. Oil is now pumped from the chamber below the piston to the pressure chamber above the piston. The oil pressure causes the piston to move downward, thereby opening the valve against the pressure of the closing spring. The pump remains energized until the closing command is given. When power is removed, or in the event of a power failure, the pump will be deactivated and the control valve opened so that the closing spring pushes the piston back. The return flow system is sized such that the counterstroke required for reaching the fully closed position is completed within about 0.6 seconds. June of 165 TD/TAD4 Manual Rev 4

148 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

149 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

150 Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

151 12.6 VPS 504 Valve Proving System Operating Instructions For TD/TAD4 Dual Fuel Burner The VPS 504 is the valve proving system used for double block gas valves. The valve proving system complies with EN 1643: Equipment operates independent of residual pressure in the range of the permissible operating range Test volume 4 l Setting work not necessary on site Short test period: min. 10 s, max. 26 s Tightness or leaks are displayed by an LED External fault display possible for series 02, series 04 and series 05. Group fault alarm optional for series 01 (SSM) Suitable for TRD systems Electrical connection possible by plug connection series 01, 02, 03. No rewiring is required for contact allocation as per DIN Series 04 and series 05: electrical connection at screw terminals via PG 13.5 cable entry. Suitable for gases of gas families 1, 2, 3 and other neutral gaseous media. Not suitable for use with hydrogen VDK 200 H2 to be used for hydrogen. Approvals EC type test approval as per EC Gas Appliance Directive: VPS 504 CE-0085 AP 0168 EC type test approval as per EC Pressure Equipment Directive: VPS 504 CE Hall switch 2 Solenoid 3 Pressure switch diaphragms 4 Compression spring 5 Filter 6 Solenoid valve anchor 7 Solenoid valve coil 8 Pressure pump 9 Unlock switch 10 Fault lamp 11 Operating lamp 12 Test nipple 13 Volume restrictor 14 Pump diaphragm 15 Pump linkage 16 PCB 17 Plug connection 18 Equipment fuse 19 Spare fuse June of 165 TD/TAD4 Manual Rev 4

152 Specifications Operating pressure Test volume Pressure increase by motor pump Nominal voltage (Permissible voltage range) max. 500 mbar (50 kpa) 4.0 l 20 mbar Operating Instructions For TD/TAD4 Dual Fuel Burner 230 V AC (-15%) to -240 V (+6%), VPS 504 series 05: 24 VDC For further voltages, refer to type overview Frequency Rating requirement Prefuse (provided by customer) Fuse installed in housing cover, replaceable Switching current VPS series 01-04: 50 Hz or 60 Hz Series 05: DC During pumping time approx. 6 VA, in operation 17 VA 10 A quick-acting or 6.3 A slow-acting fuse Microfuse 6.3 slow-blow L 250 V; IEC-127-2/III (DIN ) Operating output VPS 504 Series 01, 02, 03, 04, 05: max. 4 A Interference output VPS 504 Series 02, 04, 05: max.1a Refer to motor startup current! Degree of protection VPS 504 Series 01, 02, 03: IP 40 VPS 504 Series 04, 05: IP 54 Ambient temperature 50 Hz 230 VAC -15 C to +70 C others: -15 C to +60 C Release time Approx s, depending on test volume and input pressure Sensitivity limit Switch-on duration of control max. 50 l/h At inlet pressures of < 50 mbar, limit pressure rates well below 50 l of air per hour occur due to the mode of operation. This allows for applications involving low inlet pressures. 100 % ED Max. number of test cycles 20/h. Wait for at least 2 minutes after carrying out more than 3 consecutive test cycles. Installation position Media Standard model Liquefied gas model vertical, horizontal, not upside down Gas families 1, 2, 3 and other gaseous media. Not suitable for butane. Gas family 3 and butane The VPS 504 operates depending on pressure build-up. The program module starts to function when heat is requested. Test is performed depending on the burner functional procedure: Check prior to burner start or Check during pre-purge period or Check after burner shut-down June of 165 TD/TAD4 Manual Rev 4

153 Operating Instructions For TD/TAD4 Dual Fuel Burner Electrical Connections June of 165 TD/TAD4 Manual Rev 4

154 12.7 Variotronic VT Oil Metering Valve Operating Instructions For TD/TAD4 Dual Fuel Burner General Description The Variotronic oil valve has been designed to work primarily in conjunction with electronic positioning motors for the accurate control of fluids, fuel oils and liquids as defined in the specification of recommended applications. The design of the valve incorporates an adjustable linear characterising spool which enables the valve to operate to a virtually linear characteristic. the characterising spool adjusts the output of the valve in relation to the metering valve spindle. This changes the flow rate of the valve - thus ensuring that the maximum angular rotation is utilised to optimise the flow accurately Construction The valve construction consists of a carbon steel body which is drilled at each end to accommodate the valve output port and the valve retaining cap. The output port is secured by 6 screws with an oil seal 'O' ring sealing the face of the end cap and valve body. An identical construction is on the drive end of the valve. The end cap has a duel function in retaining the spool sleeve and providing a clamp for adjustment. The valve control flow spindle is mounted directly through the spool and retained by the output port plate. This also has a duel function acting as a surface thrust plate for the valve control. When the valve is used in conjunction with an electronic servo motor, there are mounting pillar locations provided at 52mm hole centres (which is the European standard for the 4Nm required torque for operating this type of valve.) Valve Maintenance All rotating valves do eventually require maintenance, but maintenance is only generally necessary as a result of wear on oil seals or 'O' rings. as a general guide we recommend that 'O' rings are normally re-placed every 2 years or 20,000 hours, but this could vary on the type of fuel being used, generally when operating on heavy fuel oils the service frequency should be reduced to 12 months. The normal grade of 'O' ring seals fitted within the valve is Viton. Special materials are available for corrosive or fuels that contain corrosive substances. The general service and maintenance of the valve is a very simple operation and all the seals could be changed within a matter of minutes. It is essential to ensure that all replacement seals are of the correct specification, any deviation from the specification could lead to premature seal failure and even leakage from either the valve spindle or retaining faces Changing Seals It is recommended that a spare set of seals is always retained for service and maintenance of the valve. Changing the seals is a relatively simple task. A. Isolate all electrical and fuel supplies B. Ensure that the valve is cold and that there is zero pressure within the hydraulic circuit C. Disconnect the valve drain mechanism, either mechanically or via electric servomotor D. Before dismantling the valve, ensure that the positions are appropriately marked so that the re-assembly, particularly of the spool ring can be repeated to the original settings. Remove the 2 pillars securing the index plate. this will then expose the 4 countersunk retaining screws on the valve retaining cap. The valve can then be de-assembled. June of 165 TD/TAD4 Manual Rev 4

155 Operating Instructions For TD/TAD4 Dual Fuel Burner E. The entire metering spindle and spool sleeve can be removed from the top plate. The spindle has a Viton 'O' ring and there is a Viton 'O' ring between the cap and the valve body. the shaft sealing is via 2 x 'O' rings which are submersed inside the spool sleeve. There should not be any need to remove the bottom plate, although as a precautionary measure if 'O' rings are being replaced, it is good practice to replace all of the seals with the correct specification for the valve Adjustment of the valve Since the valve can operate either for spill back nozzles or for direct metering of fuel, the configuration can be changed by indexing the pool witness mark to change the opening and closed characteristic of the valve. In other words, when the witness plate is indexed to position 'A' the valve operates from closed to open over the 90 degree scale. When the witness plate is indexed to position 'B', the valve operates from fully open to closed over a 90 degree movement. It is also possible to change the flow characteristic of the valve by changing the position of the spool in accordance with the details on the flow graph and scale plate indicators. Valve adjustment is extremely simple. The design of the valve allows maximum travel from 0 to 90 degrees to control the modulating range of the burner. Depending upon the flow rate required across the valve, this could control fuel flows in excess of 20:1 over the valve spindle angular movement. It is possible to adjust the output of the valve whilst still maintaining the large amount of linearization by adjusting the spool ring on the inner scale plate. This is adjusted by loosening the retaining cap and rotating the spool with a peg spanner. The index mark on the spool indicates the spool position which can be read in conjunction with the flow charts on the opposite page Installation of the valve The Variotronic valve can be mounted in any access. it is however, essential that there is no pipe stress from either the inlet or discharge port of the valve. Any external pressure caused from pipe stress could distort or cause the valve to malfunction. Fixing of the valve is via a pad with 2 off tapped holes, 5MM tapped directly into the valve body Valve Drive While the Variotronic valve has primarily been designed to be driven by an electronic positioning motor, it is possible to use the valve via mechanical linkage. It is essential that there is zero play on any connection between the valve spindle and the drive to the valve. This is particularly important with electronic positioning since the valve is normally controlled by a sensor or potentiometer mounted directly on the servo motor shaft. Zero hysteresis drive couplings must be used or, alternatively, a solid coupling between the servo motor and valve spindle. Before commencing operation of the valve, please ensure that there is oil or lubrication within the valve. Do not run the valve dry as this could affect the long term accuracy. If the valve has to be operated before the oil system has been fully primed, it is prudent to put lubricating oil in the valve ports. June of 165 TD/TAD4 Manual Rev 4

156 Exploded Diagram Operating Instructions For TD/TAD4 Dual Fuel Burner June of 165 TD/TAD4 Manual Rev 4

157 12.8 DH Series Pump Operating Instructions For TD/TAD4 Dual Fuel Burner `DH` SERIES GENERAL DESCRIPTION The oil pump is a vital part of any oil fired heating plant, whether being used as a transfer pump for pumping oil at low pressures or on an oil burner delivering oil at 35 bar. The Dunphy DH series pump has been specifically designed to overcome the problems associated with current grades of fuel oils in a variety of different situations, giving accurate pressure control combined with reliability and performance. The pump housing is Grade 14 cast iron that is precision machined to accept the various combinations of gear sets that are available to suit a wide variety of applications. Exhaustive work on test rig and field trials that internal leakage s in a gear pump are most severe through the lateral running clearances. They are less severe through the radial clearances, here, the leakage path is long and the rotation of the gears opposes the pressure gradient. Based on these observations a `Sandwich` construction of the gear-set and the pumping chamber has been designed from first principles. Calculations and computer modelling gave clear figures for the very high bearing loads resulting from high liquid pressure acting on the projected area of the gears. As a result, the design has catered for bearings of large surface area. This must result in minimal rubbing speed. They must also provide rigid shaft support with no appreciable deflection. The final design provides all DH series with gear-sets of nitrogen hardened steel supported by an extremely strong bearing assembly. It enables the standard unit to handle fuels with viscosities from 2 up to 2000 centistokes at pressures up to 35 bar and temperatures of up to 140ºC. Single or tandem gear-sets can be offered as standard. Pumps with special series gear-sets can be offered for specific applications. The most characteristic and frequent failure of oil pumps is that of pump seizure. In operation, a gear pump is required to deliver the maximum possible volume for a given centre distance and face-width of the gears. Losses due to internal leakage must be minimal and sufficient only to provide adequate lubrication of the rotating parts. However, the capacity of the gear-set depends on the depth of the gear tooth. Design must therefore cater for a minimum number of teeth and for minimum peripheral rubbing speeds These parameters were used in making a choice between an internal pinion and rotor format and an external gear-set employing straight spur gear teeth of corrected involute form. Dunphy engineers chose the external gear-set because it provides maximum capacity for minimum peripheral rubbing speeds. This factor is of vital importance in the elimination of pump seizure. June of 165 TD/TAD4 Manual Rev 4

158 Pressure Regulation A pressure regulating valve is provided as a standard feature of the pump. It is located within the pump body and consists of a steel piston with P.T.F.E. wipers that slides in a honed steel bore. Pressure is exerted on the piston itself by a spring, the loading of which is adjustable by the user. The pressure of the oil bears on the cross sectional area of the piston. Operating Instructions For TD/TAD4 Dual Fuel Burner When oil pressure and spring force balance, the piston lifts and permits by-passed oil to return to the suction port. The accuracy of the machining and honing ensures that the close fitting piston is kept in contact with the cylinder bore by the pressure of oil acting on its annular area This combination of material selection and fine tolerance eliminates edge filtration, prevents sticking in operation and reduces hysteresis effects to an absolute minimum. The Dunphy DH Series of oil pumps has been purposefully designed, in-house, to a demanding brief, by experienced engineers who have learned, at plant level, what qualities the user demands of an oil pump. This facility eliminates the need to insulate the pump and the flexible's and ensures that both are kept at the correct temperature. As a result the DH oil pump has been designed up to an extremely high quality standard. For heavy oil installations, the DH pump can be fitted with a restrictor which will allow oil from the ring main system to circulate through the flexible oil lines and also the pump body when the burner is not running. June of 165 TD/TAD4 Manual Rev 4

159 VOLUMETRIC EFFICIENCY Technical Data Summary Operating Instructions For TD/TAD4 Dual Fuel Burner Pump Model Code DHO-1 DH1-1 DH1-2 DH2-1 DH2-2 Gearwheel Capacity litres/hr Gearwheel Capacity gall/hr Weight - kg Shaft Diameter - mm Fuel Types C up to C Speed 3600 Revolutions per minute ( maximum ) Operating Pressures 35 bar on standard units, maximum of 60 bar on tandem units Capacity Range 145 to 4500 litres/hour ( 32 to 1000 imp gallons/hour approx ) Inlet Pressure 2 bar ( maximum ) ( 30 lbs. sq. inch ) Pump Fixing Flange or Boss Maximum Operating Temperature ( Fuel Oil ) 140 C NOTES 1. PUMP CAPACITY A number of variants can be offered. There are two basic gear-sets available in the range, these cover swept volumes from 290 to 4500 litres/hour at 2 pole ( 2850 rpm and 3400 rpm ) speed. Because running clearances in the pump are at an absolute minimum, the Volumetric Efficiency of the gear-set becomes a function of the viscosity of the liquid being pumped. ( See diagram below ). The further variants arise from the potential of using the pumps as SINGLE, SERIES or TANDEM sets as described in the diagrams below. 70% 95% SINGLE SINGLE gear-set VISCOSITY 2. CAPACITIES Capacities are given for pumps running at 2 pole speed ( 2850 rpm ) and a 50 Hz electric supply. SERIES The SERIES arrangement provides a similar CAPACITY to the SINGLE but the PRESSURE can be doubled without any increase on the bearing load. 3. GEARWHEEL CAPACITIES As stated, these give the full swept volume of the pump. TANDEM The TANDEM arrangement DOUBLES the capacity of the SINGLE gear-set June of 165 TD/TAD4 Manual Rev 4

160 Installation Operation Maintenance Installation The DH Series can be supplied for either flange or boss mounting to suit most applications. Pumps should be mounted with the shaft horizontal, but the pump body may be turned on its axis to allow easier access for pipe connections etc. It is essential that the pump and the motor drive shafts are correctly aligned, that there is no `play` in the drive connector and that there is no end pressure on either drive shaft. See the pump and motor arrangement drawing at the bottom of the page. Check that all joints on the oil supply pipes, flexible oil lines etc. are properly sealed and that the oil supply temperature and pressure are correct ( see the relevant burner manual for guidance notes on oil installation, remembering that the maximum permissible oil supply pressure to DH series pumps is 2 bar. Residual fuel oils should be supplied to the inlet port of oil burner pumps at temperatures of: 40ºC for 200 secs R1 ( 13.5 cst at 80ºC ) 65ºC for 960 secs R1 ( 35 cst at 80ºC ) 80ºC for 4000 secs R1 ( 85 cst at 80ºC ) When DH series pumps are used with air/steam atomised burners burning residual fuel oils the oil supply temperatures can be reduced to: 10ºC for 200 secs R1 ( 13.5 cst at 80ºC ) 30ºC for 960 secs R1 ( 35 cst at 80ºC ) 45ºC for 4000 secs R1 ( 85 cst at 80ºC ) P U M P P U M P F L A N G E A D A P T O R A N D S C R E W S H O U S IN G C O V E R A N D S C R E W S H O U S IN G P A R A L L E L K E Y C O U P L IN G A N D S E T S C R E W S C O U P L IN G IN S E T D R IV E M O T O R TYPICAL ARRANGEMENT OF PUMP, MOTOR AND DRIVE COUPLING Operating Instructions For TD/TAD4 Dual Fuel Burner Distillate fuel oils should be supplied to the pump inlet port at a slight positive pressure. Where suction lift is required, the Dunphy technical department should be consulted. Residual fuel oils should be supplied to the pump inlet port at a pressure between 1 and 2 bar Filtration Filters must be fitted in the oil supply system to prevent foreign matter entering the pumps and possibly affecting performance or causing physical damage. All DH1 fuel are supplied with internal filters, however, when pumps are used with residual fuel oils, it is recommended that this filter is removed after approximately one weeks running when it is certain that any swarf or other foreign matter has been thoroughly flushed out of the oil supply lines. DH2 pumps do not have an integral filter Oil Re-Circulation When supplied for use on heavy oil installations all `DH` series pumps are fitted with a restrictor with a 4mm diameter orifice fitted between the oil inlet and ring main return ports. This allows the flow of oil to circulate from the ring main system, through the flexible oil lines and pump and into the ring main return, effectively keeping both the pump and the flexible oil lines warm, eliminating the need for lagging and trace heating. The pumps can be fitted with restrictors with a larger orifice size, but care must be taken when fitting these that the re-circulation does not depress the ring main capacity as this is a direct bleed between the flow and return DH (P) Fuel Pumps ( Light oil) All `DH` series pumps with the prefix `P` are fitted with a manifold on the oil return port that allows a flow of oil back into the return while the burner is `purging`. This allows the pump to automatically prime itself every time the burner goes through its starting cycle and eliminates the need for mechanical venting. June of 165 TD/TAD4 Manual Rev 4

161 Fault Finding Symptom or Fault Operating Instructions For TD/TAD4 Dual Fuel Burner Probable Cause Pump motor runs, but no oil delivered. Pump coupling loose on either pump side or motor side. Fuel starvation. Oil system air locked. Pump seized. Pump shaft broken. Pump rotates but no oil passing from nozzle. Burner solenoid valves not opening. Blocked atomising nozzle. Fuel starvation. Pump noisy. Gas or air in pump Pump worn. Blocked line filters. Fluctuating Oil Pressures. Dirt in regulating valve. Insufficient pressure in pumped ring main to suppress gas formation in the suction side of the pump. High vacuum at pump suction. Fuel starvation. Worn pump. Pump drive slipping. Air leakage into the system. Low Oil Pressures. Pump undersized. Pump worn. Defective solenoid valve. Oil starvation/defective metering system. Regulating valve stuck. Pump Overheats. Pump oversized. Miss-alignment of pump drive. Dirt in oil. June of 165 TD/TAD4 Manual Rev 4

162 RETURN FROM BURNER SHOWN OUT OF POSITION FOR CLARITY RETURN FROM BURNER SHOWN OUT OF POSITION FOR CLARITY Oil Flow Diagrams Operating Instructions For TD/TAD4 Dual Fuel Burner ROTATION ROTATION OIL RETURN OIL UNDER PRESSURE OIL UNDER SUCTION PLAN VIEW PLAN VIEW PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PLUG OR VACUUM GAUGE PRESSURE REGULATOR OIL OUTLET TO NOZZLE PLUG OR SUCTION RETURN PLUG OR SUCTION RETURN OIL INLET ½" B.S.P.P. OIL INLET ½" B.S.P.P. ALTERNATIVE OIL INLET ALTERNATIVE OIL INLET OIL FLOW DIAGRAM FOR TYPE DH1 FUEL PUMPS ROTATION ROTATION OIL RETURN OIL UNDER PRESSURE OIL UNDER SUCTION PLAN VIEW PLAN VIEW PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PLUG OR VACUUM GAUGE PRESSURE REGULATOR OIL OUTLET TO NOZZLE PLUG PLUG OIL RETURN OIL INLET OIL INLET OIL RETURN OIL FLOW DIAGRAM FOR TYPE DH1 (P) FUEL PUMPS June of 165 TD/TAD4 Manual Rev 4

163 RETURN FROM BURNER SHOWN OUT OF POSITION FOR CLARITY RETURN FROM BURNER SHOWN OUT OF POSITION FOR CLARITY Operating Instructions For TD/TAD4 Dual Fuel Burner ROTATION ROTATION OIL RETURN OIL UNDER PRESSURE OIL UNDER SUCTION PLAN VIEW PLAN VIEW PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PLUG OR VACUUM GAUGE PRESSURE REGULATOR PLUG OR SUCTION RETURN OIL OUTLET TO NOZZLE PLUG OR SUCTION RETURN OIL INLET ½" B.S.P.P. OIL INLET ½" B.S.P.P. ALTERNATIVE OIL INLET ALTERNATIVE OIL INLET OIL FLOW DIAGRAM FOR TYPE DH2 FUEL PUMPS ROTATION ROTATION OIL RETURN OIL UNDER PRESSURE OIL UNDER SUCTION PLAN VIEW PLAN VIEW PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PLUG OR VACUUM GAUGE PRESSURE REGULATOR OIL OUTLET TO NOZZLE PLUG PLUG OIL OUTLET OIL INLET OIL INLET OIL OUTLET OIL FLOW DIAGRAM FOR TYPE DH2 (P) FUEL PUMPS June of 165 TD/TAD4 Manual Rev 4

164 Operating Instructions For TD/TAD4 Dual Fuel Burner litres/hr 3000 NOTES 2000 DHO-1 kw 4 3 DH2-2 DH DH2-1 DH1-1 DH2-1 DH1-2 0 DHO bar 1 DH1-1 DHO-1 NOZZLE CAPACITY SINGLE STAGE PUMPS 2850 RPM bar litres/hr 2500 TYPICAL POWER CONSUMPTION 1425 RPM 2000 DH2-2 kw 8 DH DH2-1 6 DH2-2 DH DH1-1 DHO-1 4 DH bar NOZZLE CAPACITY SINGLE AND TWO STAGE PUMPS 1425 RPM 3 DH2-1 DH1-2 litres/hr DH1-1 1 DHO-1 DH bar TYPICAL POWER CONSUMPTION 2850 RPM 2000 DH1-2 LEGEND cst at 80ºC NOZZLE CAPACITY TWO STAGE PUMPS 2850 RPM bar 3.5 cst at 40ºC 1-2 cst at 40ºC June of 165 TD/TAD4 Manual Rev 4

165 Operating Instructions For TD/TAD4 Dual Fuel Burner DUNPHY COMBUSTION LTD QUEENSWAY ROCHDALE ENGLAND OL11 2SL Tel +44 (0) Fax: +44 (0) Internet June of 165 TD/TAD4 Manual Rev 4