Installation- and maintenance instruction B45A2.2

Transcription

1 Installation- and maintenance instruction B45A

2

3 DESCRIPTION Components 1. Flame cone 2. Fan housing 3. Fan wheel 4. Damper motor 5. Motor 6. Pump 7. Shrouded disc 8. Nozzle 9. Ignition transformer 10. Nozzle assembly 11. Air intake 12. Air damper 13. Connecting pipe Stage Connecting pipe Stage Solenoid valves 16. Nozzle assembly adjustment 17. Connecting pipe, pumpadjustment device 18. Adjustment device, Nozzle assembly adjustment 19. Fuse 20. Indicating lamp Stage Switch I-II 22. Indicating lamp Stage Switch 0-I 24. Contactor 25. Control box 26. Drive coupling 27. Conical shield plate 28. Ignition electrodes

4 TECHNICAL DATA DECLARATION OF CONFORMITY Type designation B45A2 Dimensions ø162 ø Manufacturer: Enertech AB, Bentone Division Street address: Näsvägen SE Ljungby Address: P.O. Box 309 SE Ljungby Sweden Product: Oil burner 262 Output range and nozzles recommended The net caloriic value of 11,86 kwh/kg for light oil has been used. Recommended nozzle Because of different boiler types existing on the market, with varying combustion chamber designs, it is 515 B 480 Length of burner tube Flange Measure B B45A B45A Oil capacity Capacity Recommended nozzle Recommended Pump pressure kg/h kw Mcal/h Angle Danfoss Monarch Bar B45A2 8,5-45, S, B R, PLP 14 bar not possible to state a deinite spray angle or spray pattern. Note that the spray angle and the spray pattern change with the pump pressure. Type: BF1, B 1, B 2, B 9, B 10, B 11, B 20, B 30, B 40, B 45, B 50, B 55, B 60, B 65, B 70, B 80, ST 97, ST 108, ST 120, ST133, ST 146 Certikat TÜV Süddeutschland Certiikat Nr Burner XXXXXXXX BF B B p15001 ST97, ST108, ST120, ST133, ST B9, B10, B B20, B30, B40, B B50, B60, B70, B B B65 Enertech AB declares under sole responsibility that the above mentioned product is in conformity with the following standards or other normative documents. Document: EN 267 and follows the provisions of applicable parts in the following EU Directives: 89/336/EEC Electromagnetic compatibility 73/23/EEC Low-voltage directive 89/392/EEC Machinery directive 92/42/EEC Eficiency directive In that the burner conforms to the above mentioned standards it is awarded the CE mark. Electrode adjustment Enertech AB, Bentone Division is quality certiied according to SS-EN ISO 9001:2000 Ljungby ENERTECH AB Sven-Olov Lövgren 5,0-6,0 3,5-4,0 2,0-3,0 7,0-9,

5 FAULT LOCATION TECHNICAL DATA Burner fails to start Dimensions of lange Situation Possible causes Remedies Motor runs Flame instability Burner pre-purges Flame occurs Burner locks out Motor runs Burner pre-purges No lame occurs Burner locks out Incorrect head settings Low oil pressure Excess air Photocell not seeing light Photocell failed Control faulty False light Check nozzle to burner head dimension and electrode position Check oil pressure Adjust air damper Check that photocell is clean and unobstructed Conirm with new photocell Conirm with new control. (NB. it is advisable to change the photocell if also changing control) Check that photocell is not seeing ambient light Check that H.T. leads are sound and are not arcing other than at electrode gap 14 Burner fails to start after normal operation No spark No oil Burner fails to start Fuse has blown Appliance thermostat has not reset Lamp not lit Appliance overheat device has operated Check oil supply to burner - check that pump is not airlocked Check operation of magnetic valve Check or replace fuse if necessary. Check reason for failure Adjust thermostat Reset overheat device. Find reason for its operation and rectify (ø200) ø Control relay or photocell defective Check by replacement No oil being delivered Check that tank, oil lines, ire valve, pump and nozzle are all in good order Motor runs Burner runs to lockout Excessive lue draught is preventing lame establishment No spark Rectify condition Check ignition transformer. Check electrode gap and porcelain Delayed ignition, burners starts violently Burner pulsates on start-up only with hot lue Excessive draught Adjust the burner ø134 Burner pulsates on start-up Nozzle partly blocked Oil pressure too low Flue blocked or damaged Fan slipping on shaft Pump coupling loose or worn Replace nozzle Check and adjust Check and rectify Check and retighten Check and replace Burner starts violently Delayed ignition Check the electrode adjustment, see diagram Check electrodes for damage Check H.T. leads for damage and disconnection

6 GENERAL INSTRUCTIONS NOZZLE TABLE General rules The installation of an oil burner should be carried out in accordance with local regulations. The installer of the burner must therefore be aware of all regulations relating to oil and combustion. Only oil suitable for the burner should be used and then in combination with a suitable oil ilter before the oil pump of the burner. If the burner is replacing an existing burner make sure that the oil ilter is replaced or cleaned. The installation must only be undertaken by experienced personnel. Care should be taken by the installer to ensure that no electrical cables or fuel/gas pipes are trapped or damaged during installation or service/maintenance. Installation instructions General installation instructions ac company the burner and should be left in a prominent place adjacent to the burner. Condensation in chimney A modern burner works with less excess air and often also with smaller nozzles than older models. This increases the eficiency but also the risk of condensation in the chimney. The risk increases if the area of the chimney lue is too large. The temperature of the lue gases should exceed 60 C measured 0,5 metres from the chimney top. Measures to raise the temperature: - Insulate the chimney in cold attics - Install a tube in the chimney - Install a draught regulator (dilutes the lue gases during operation and dries them up during standstill) - Increase the oil quantity - Raise the lue gas temperature by removing turbulators, if any, in the boiler. Pump adjustment See separate description. Maintenance The boiler/burner should be examined regularly for any signs of malfunction or oil leakage. Oil supply The oil line should be dimensioned in accordance with the pump manufacturer s instruction. In the suction line to the burner a ilter should be mounted to prevent any particles in the oil from reaching the burner. If the installation consists of several burners each one should have its own suction line from the tank or a circulation system should be used. The temperature in the oil line should be kept as constant as possible. Avoid exposing the line to excessive cold which may cause blockages of parafin deposits. The oil pipe and electric cable should be itted so that the burner can be placed on the loor for inspection of the combustion device. Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 1,00 5, , , , ,10 6, , , , ,20 6, , , , ,25 6, , , , ,35 7, , , , ,50 8, , , , ,65 9, , , , ,75 9, , , , ,00 11, , , , ,25 12, , , , ,50 13, , , , ,75 15, , , , ,00 16, , , , ,50 19, , , , ,00 22, , , , ,50 24, , , , Adjustment of burner The burner is from the factory pre-set to an average value that must then be adjusted to the boiler in question. All burner adjustments must be made in accordance with the boiler manufacturer s instructions.these must include the checking of lue gas temperatures, average water temperature and CO 2 or O 2 concentration. To adjust the combustion device, start by increasing the air volume and the nozzle assembly somewhat.when the burner starts it is burning with excess air and smoke number 0. Reduce the nozzle assembly adjustment until soot occurs, and then increase the adjustment to make the soot disappear again. Then the volume of air is reduced until soot occurs and increased again to reach a combustion free of soot. By this procedure an optimum adjustment is obtained. If larger nozzles are used the preadjustment of both the air volume and the nozzle assembly must be increased. A whistling sound may be heard which can be eliminated or reduced as follows: Increase the nozzle assembly adjustment somewhat. The CO 2 -content and consequently the air volume will then be reduced. Adjustment of nozzle assembly 0-13 Air adjustment See page "Air adjustment with damper motor". Adjustment of nozzle assembly A Adjustment Stage 1. B Adjustment Stage 2. 5,00 27, , , , ,50 30, , , , ,00 33, , , , ,50 35, , , , ,00 38, , , , ,50 41, , , , ,00 44, , , , ,50 46, , , , ,00 49, , , , ,50 52, , , , ,00 55, , , , ,00 60, , , , ,00 66, , , , ,00 77, , , , ,00 88, , , , The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m 3. 2(2)

7 NOZZLE TABLE AIR ADJUSTMENT Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 1,00 4, , , , ,10 5, , , , ,20 5, , , , ,25 6, , ,58 78, 67 6, ,35 6, , , , ,50 7, , , , ,65 8, , , , ,75 8, , , , ,00 9, , , , ,25 11, , , , ,50 12, , , , ,75 13, , , , ,00 14, , , , ,50 17, , , , ,00 19, , , , ,50 22, , , , ,00 24, , , , The damper motor turns the damper between 3 preset positions: These positions are controlled in the motor by cams which are set by means of the coloured disks. In addition there is a black disk controlling the connection of solenoid valve 2 and a green disc controlling the connection of solenoid valve 3. If the air volume needs changing: Remove the cover from the damper motor and change the position of the cams by turning them with the tools accompanying the burner. Stage 1: Adjust the operating switch to stage 2 (II). * Reduce the air volume: Turn blue cam towards 0. * Increase the air volume: Turn blue cam towards 90. Adjust the operating switch back to stage 1 and check. Stage 2: Adjust the operating switch to stage 1 (I). * Reduce the air volume: Turn orange cam towards 0. * Increase the air volume: Turn orange cam towards 90. Adjust the operating switch back to stage 2 and ensure that the correct air volume has been obtained. Stage 3: Adjust the operating switch to stage 2 (II). * Reduce the air volume: Turn red cam towards 0. * Increase the air volume: Turn red cam towards 90. Adjust the operating switch to stage 3 (III) and ensure that the correct air volume has been obtained. NOTE On adjustment of stage 2 and stage 3 the black cam (Mv2) must be within the settings of the blue and orange cams and the green cam (Mv3) within the settings of the orange and the red cams. Releasing button By pressing the button and snapping it down, the motor will be released and the damper can easily be turned. This function facilitates an exchange of damper motor. 5,50 27, , , , ,00 29, , , , ,50 32, , , , ,00 34, , , , ,50 37, , , , ,00 39, , , , ,50 42, , , , ,00 44, , , , Solenoid valve stage 3 (green) 9,50 47, , , , ,00 49, , , , Solenoid valve stage 2 (black) 11,00 54, , , , ,00 59, , , , Stage 3 (red) 14,00 69, , , , ,00 79, , , , Stage 2 (orange) The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m 3. Stage 1(blue) Releasing button N.B. The upper position is the standard position 1(2)

8 MAINTENANCE OF OIL BURNER NOZZLE TABLE Warning: Before doing any service switch off power at the main switch and cut off the oil supply. Service of burner head (alt. A) Service of burner head (alt. B) Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 1,00 4, , , , ,10 4, , , , ,20 5, , , , ,25 5, , , , ,35 5, , , , ,50 6, , , , ,65 7, , , , ,75 7, , , , ,00 8, , , , ,25 9, , , , ,50 11, , , , ,75 12, , , , ,00 13, , , , ,50 15, , , , ,00 17, , , , ,50 19, , , , ,00 22, , , , ,50 24, , , , ,00 26, , , , ,50 28, , , , ,00 30, , , , ,50 33, , , , ,00 35, , , , ,50 37, , , , ,00 39, , , , ,50 41, , , , ,00 44, , , , ,00 48, , , , ,00 52, , , , ,00 62, , , , ,00 70, , , , ,00 79, , , , ,00 88, , , , ,00 96, , , , ,00 105, , , , ,00 114, , , , The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m 3. Note! For maintenance of the brake plate, nozzles, electrodes etc, when using a long design of the burner tube, you have to remove the nozzle assembly from the connecting pipe and move the assembly backwards in the fan housing (from the boiler). 2(2)

9 NOZZLE TABLE ELECTRIC EQUIPMENT Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 1,00 3, , , , ,10 4, , , , ,20 4, , , , ,25 4, , , , ,35 5, , , , ,50 5, , , , ,65 6, , , , ,75 6, , , , ,00 7, , , , ,25 8, , , , ,50 9, , , , ,75 10, , , , ,00 11, , , , ,50 13, , , , ,00 14, , , , ,50 16, , , , ,00 18, , , , ,50 20, , , , ,00 22, , , , ,50 24, , , , ,00 26, , , , ,50 27, , , , ,00 29, , , , ,50 31, , , , ,00 33, , , , ,50 35, , , , ,00 37, , , , ,00 40, , , , ,00 44, , , , ,00 52, , , , ,00 59, , , , ,00 67, , , , ,00 74, , , , ,00 81, , , , ,00 89, , , , ,00 96, , , , The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m 3. Oil burner control: LAL1... Wiring diagram Damper position If S6 is missing connection between L1 and L2. If S9 is missing connection between T6 and T8. 3N ~50/60Hz 400/440 V 1(2) (3)

10 ELECTRIC EQUIPMENT NOZZLE TABLE Oil burner control: LAL1... List of components A1 Oil burner control B1 Photoresistor F1 Operating fuse F2 Fuse F3 Fuse H1 Lamp, Stage 1 H2 Lamp, Stage 2 H3 Lamp, Stage 3 K1 Thermal overload protection M1 Burner motor M2 Damper motor L&S SQN75.436A21B P1 Time meter, Stage 1 P2 Time meter, Stage 2 P3 Time meter, Stage 3 S1 Operating switch S2 Operating switch, Stage 2 S3 Control thermostat S4 Temperature limiter S5 Micro switch for hinged door Mains connection and fuse in accordance with local regulations. Function 1. Operating switch ON, Twin thermostat ON, Air damper closed The burner motor starts. 2. Ignition spark is formed Ignition spark is formed. Air damper motor opens the damper to stage Air damper motor closes The air damper motor closes to stage Solenoid valve 1 opens The oil mist is ignited. The photoresistor indicates a lame. 5. The safety time expires a. If there is no lame established before this time limit, the burner control locks out. b. If the lame for some reason disappears after this time limit, the burner control also locks out. If a repetition of the start-up sequence is desired, the wire link marked "Repetition" on the side of the base plate of the control must be removed. 6. Thermostat and switch Stage 2 ON The burner can now change over to stage Thermostat and switch Stage 3 ON The burner can now change over to stage Operating position The burner can now change between stage 1, 2 and 3. The burner operation is interrupted by means of the operating switch or the thermostat. The control locks out A red lamp in the control is lit. Move the transparent cover aside and restart the burner by pressing the reset button. S6 Control thermostat, Stage 2 S7 Main switch S8 Operating switch, Stage 3 S9 Control thermostat, Stage 3 S20 Main switch T1 Ignition transformer X1 Connection terminal board X2 Earth terminal X3 Plug-in contact "Euro", burner X4 Plug-in contact "Euro", boiler X5 Plug-in contact "Euro", stage 3 burner X6 Plug-in contact "Euro", stage 3 boiler X7 Plug-in contact "Euro" 3-phase, burner X8 Plug-in contact "Euro", 3-phase, boiler X9 Plug-in contact "Euro", stage 2 burner X10 Plug-in contact "Euro", stage 2 boiler Y1 Solenoid valve 1 Y2 Solenoid valve 2 Y3 Solenoid valve 3 Y1S Safety solenoid valve (Standard on burners with an output 100 kg/h) (Option on burners with an output < 100 kg/h) Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 0,40 1, , , , ,50 2, , , , ,60 2, , , , ,65 2, , , , ,75 3, , , , ,85 3, , , , ,00 4, , , , ,10 4, , , , ,20 4, , , , ,25 5, , , , ,35 5, , , , ,50 6, , , , ,65 6, , , , ,75 7, , , , ,00 8, , , , ,25 9, , , , ,50 10, , , , ,75 11, , , , ,00 12, , , , ,50 14, , , , ,00 16, , , , ,50 18, , , , ,00 20, , , , ,50 22, , , , ,00 24, , , , ,50 26, , , , ,00 28, , , , ,50 30, , , , ,00 32, , , , ,50 34, , , , ,00 36, , , , The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m 3. Burner with preheater Consider that on preheating the oil quantity is reduced by 5-20% depending on. - Rise in temperature at the nozzle - Design of nozzle - Capacity (high capacity - small difference) Note! In the window of the control symbols appear showing in which position the control locks out, see Control programme under fault conditions and lock-out indication. 2(3) (2)

11 NOZZLE TABLE ELECTRIC EQUIPMENT Pump pressure bar Gph kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h kg/h kw Mcal/h 0,40 1, , , , ,50 1, , , , ,60 2, , , , ,65 2, , , , ,75 2, , , , ,85 2, , , , ,00 3, , , , ,10 3, , , , ,20 3, , , , ,25 4, , , , ,35 4, , , , ,50 4, , , , ,65 5, , , , ,75 5, , , , ,00 6, , , , ,25 7, , , , ,50 8, , , , ,75 9, , , , ,00 9, , , , ,50 11, , , , ,00 13, , , , ,50 14, , , , ,00 16, , , , ,50 18, , , , ,00 19, , , , ,50 21, , , , ,00 23, , , , ,50 24, , , , ,00 26, , , , ,50 28, , , , ,00 29, , , , The table applies to oil with a viscosity of 4,4 mm 2 /s (cst) with density 830 kg/m 3. Burner with preheater Consider that on preheating the oil quantity is reduced by 5-20% depending on. - Rise in temperature at the nozzle - Design of nozzle - Capacity (high capacity - small difference) Oil burner control: LAL1... Control programme under fault conditions and lock-out indication In the event of fault conditions the sequence switch stops and simultaneosly the lock-out indicator. The symbol appearing above the reading mark indicates kind of fault: 1 No start, because e.g., the CLOSE signal has not been supplied to terminal 8 by the limit switch, or a contact has not been closed between terminals 4 and 5. Shut-down of start-up sequence, because the OPEN signal has not been supplied to terminal 8 by the limit switch. Terminals 6, 7 and 15 remain under voltage until the fault is corrected. Lock-out due to a fault in the supervision circuit. Shut-down of start-up sequence, because the position signal for the low-lame position has not been supplied to terminal 8 by the auxiliary switch. Terminals 6, 7 and 15 remain under voltage until the fault is corrected. Lock-out, because no lame signal has been received on completion of the saftey time. Lock-out, because the lame signal has been lost during burner operation or air pressure failure has occurred. Lock-out on completion or after completion of control programme sequence due to extraneous light (e.g. lame not extiguished, leaking fuel valves) or due to a faulty lame signal (e.g. fault in lame supervision circuit or similar). a - b Start-up sequence b - b "idle steps" up to the self shut-down of the sequence switch b ( b ) - a Post-purge sequence a b b Technical data Pre-ignition time: From start Pre-purge time with full air volume: 22 s Safety time: 5 s Post-ignition time: 15 s Interval between Mv1 and Mv2: 7,5 s Reset after lock-out: Immediately Time of re-start: 47 s Ambient temperature: - 20 to + 60 C Min. required current at 220 V and 95/105 µ A Max. current: 160 µ A Protective standard: IP4 1(2) (3)

12 INSTRUCTIONS PUMP TYPE SUNTEC AT2 55C INSTRUCTIONS PUMP SUNTEC AT2 Technical data Viscosity range: 2-12 mm 2 /s Pressure range: 8-25 bar Rated voltage of coil: 220/240V 50/60 Hz Oil temperature: max 60 C Components 1. Pressure adjustment Stage 1 2. Pressure gauge port G 1/8" 3. Nozzle outlet G 1/8" 4. Pressure gauge port G 1/8" 5. Vacuum gauge port G 1/8" 6. Return line G 1/4" and internal by-pass plug 7. Suction line G 1/4" 8. Return plug 9. Pressure adjustment Stage 2 Suction line tables The suction line tables consist of theoretically calculated values where the pipe dimensions and oil velocity have been matched so that turbulences will not occur. Such turbulences will result in increased pressure losses and in acoustic noise in the pipe system. In addition to drawn copper piping a pipe system usually comprises 4 elbows, a non-return valve, a cut-off valve and an external oil ilter. The sum of these individual resistances is so insigniicant that they can be disregarded. The tables do not include any lengths exceeding 100 m as experience shows that longer lengths are not needed. The tables apply to a standard fuel oil of normal commercial quality according to current standards. On commissioning with an empty tube system the oil pump should not be run without oil for more than 5 min. (a condition is that the pump is being lubricated during operation). The tables state the total suction line length in metres at a nozzle capacity of 3,0 Gph. Max. permissible pressure at the suction and pressure side is 2,0 bar. For two-pipe system Q max = 55l/h pump capacity at 0 bar. H 1-pipe system Height Pipe diameter H ø4 mm ø6 mm ø8 mm m m m m 4, , , , , , Two-pipe system Height Pipe diameter H ø6mm ø8mm ø10mm m m m m 4, , , , , , H 1-pipe system Height Pipe diameter H ø6 mm m m With an underlying tank a 1-pipesystem is not recommended Two-pipe system Heigt Pipe diameter H ø6mm ø8mm ø10mm m m m m 0, , , , , , Pump operating principle The oil pump has a built in solenoid valve which controls the regulator cut-off valve giving fast cut-off and cut-on function independent of the rotational speed. The gear-set draws oil from the tank through the built-in ilter and transfers it to the valve that regulates the oil pressure to the nozzle line. All oil which does not go through the nozzle line will be dumped through the valve back to the return line or, if it is a one-pipe installation, back to the suction port in the gear-set. - Two-pipe operation When the solenoid valve is nonactivated, the by-pass channel between the pressure and return sides of the valve is open. No pressure will then be built up to open the valve. It does not matter which speed the gear set has. When the solenoid is activated, this by-pass channel will be closed and because of the full speed of the gearset, the pressure necessary to open the valve will be built up very rapidly which gives a very sharp cut-on function. - One-pipe operation Bleeding on one-pipe is not automatic, and a pressure port must be opened to bleed the system. Exchange of ilter By-pass solenoid valve closed By-pass solenoid valve open Low pressure adjustment High pressure adjustment Vacuum gauge ports Gear set Blocking solenoid valve open Pressure outlet or pressure gauge port By-pass plug Cut-off When the burner stops, the solenoid opens the by-pass at the same moment which drains all the oil down to the return and the nozzle valve closes immediately. This gives a very sharp cut-off function. The cut-on and off can be regulated regardless of motor speed and has an extremely fast response. When the solenoid is non activated, the torque requirement is low up to full motor speed. Pressure gauge ports To nozzle Shaft seal Back to suction Blocking solenoid valve closed Suction Return One pipe installation Two pipe installation Shaft rotation and nozzle location C: Anti-clock. rotation/ Left hand nozzle (seen from Shaft end) Gear set capacity (see pump capacity curves) Standard model AT:Solenoid valve with cut-off AT 2 XX C Mounting/dismounting return plug One pipe system Two pipe system Oil under suction Oil under pressure By-passed oil returned to tank, or to suction