description and maintenance · 2018. 5. 1. · aalborg industries ii. specification thermal fluid...

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AALBORGI N D U S T R I E S

DESCRIPTION AND MAINTENANCE

OF

THERMAL FLUID INSTALLATION

Astillero Barreras

Hull no. 1594-1595

Project no. 10019A.OO- 10020A.OO

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I. GENERAL

Thermal fluid installation for:

Shipyard:

Hull no.

Class

Delivered by

Telephone

Telefax

E-mail

Project no.

Piping diagram

Electrical diagram

Fuel oil diagram

Astillero BarrerasHijos de J.Barreras S.A.36208 VigoSpain

1594-1595

Det Norske Veritas

Aalborg Industries NL BVP.O. Box 1453200 AC SPIJKENISSEThe Netherlands

(31)181-650500

(31)181-650501

[email protected]

10019A.OO-10020A.OO

D11328

D11343

D11379

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II. SPECIFICATION

Thermal fluid heater

TypeCapacity

25-VO-081,000 kW

8,60,000 kcal/h

Burner

MakeType

WeishauptRMS 7

Flue gas sensor

MakeTypeScale 200 - 500

JumoATH-7°C

Maximum thermal fluid sensor

MakeTypeScale

JumoATHs-250 - 300 °C

Differential pressure switch

MakeType

Wiesloch702.02.100

Temperature controller oil fired heater

MakeType

Wiesloch93 WOO 701

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Temperature sensor

MakeType

WieslochPT 100 Ohm

Circulating pumps

MakeTypeCapacityDelivery headE-motorCurrentMotor make

687522

3 x 440 Volt

AllweilerNTT 50-200m3/hm.l.c.kW-60 Hz

Economiser 1

TypeCapacity •Number

EXV631-31-57.0-1150 DD900 kW

1

Economiser 2

TypeCapacityNumber

EXV 631-31-57.0-1150 DD900 kW

1

Temperature controller economiser

MakeType

Wiesloch93 W01 701

Pneumatic actuator economiser

MakeType

BarGTE 163/090-10

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Minimum flow valve

MakeBoreType valveType actuator

ARIDN 65

23441PR2.2

Electronic pressure controller for minimum flow

MakeTypeRange

Wiesloch93 W01 70E

0 - 6 bar

Pressure transmitter for minimum flow

MakeTypeRange

DanfossMBS 33 Mrel

0 - 8 bar

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III. DESCRIPTION OF THE THERMAL FLUID PLANT

Yardnr. : 1594-1595Flow diagram nr. : D11328Electric diagram nr. : D11343Pneumatic diagram nr. :Aalborg Project nr. : PP10019A.OO/PP10020A.OO

The thermal fluid plant is built up from the following components:

A fired thermal fluid heater / eco flowtherm type 25-VO-08 having a capacity of 8,60,000kcal/h(l,OOOkW).

Two economisers type EXV631-31-57.0-1150 DD, each having a capacity of 774,000kcal/h (900 kW).These economisers are mounted in the exhaust gas pipelines of the main engines.

Two thermal fluid circulating pumps type NTT 50-200 of which one pump is stand-by. Onepump takes care of the liquid circulation through the entire system. Should the runningpump break down, the stand-by pump will automatically start up.

A minimum flow controller mounted between the supply and return line of the system.These controllers take care of the maintenance of the minimum flow through the firedheater and the economisers.

An expansion tank to compensate the increase hi volume of the thermal fluid.

The venting possibility at the highest point of the plant must not be forgotten.

The heat consumers are connected behind the afore-mentioned components, such as bunkertanks, settling tank, daily service tank, separator-heaters, booster heater, heater for centralheating systems and so on.

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A) The oilfired thermal fluid heater

The fired heater is provided with a burner, make Weishaupt type RMS9, automatically setto the required temperature.The fired heater is provided with the following control and safety devices:

-1 Electronic temperature control device, make Wiesloch type 93 WOO 701 in combinationwith 1 PT 100 ohm temperature measuring element.The measuring element is mounted in the supply manifold of the fired heater. Thiscombination is set to a temperature of 190°C for partial load and for full load to atemperature of approx. 185°C. Should the temperature of the thermal fluid drop belowthese values, which implies that the heat consumers require more heat than provided by theeconomisers, the fired heater will automatically start.

-1 Maximum thermostat, make Juchheim type ATHs-2 (TA-HH), mounted in the supplymanifold of the fired heater.The heater coil is guarded by a max. thermostat, set point 220°C.In case this temperature is exceeded, the fired heater is disconnected and interlocked.

-1 Flue gas thermostat, make Juchheim, type ATH-7 (TA-HH), mounted in the flue gas outletof the fired heater. This thermostat should be set to a temperature being 50°C higher thanthe flue gas temperature measured at a clean fired heater.Set point approx. 350°C.

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-1 Minimum flow pressure transmitter, type MBS 33 Mrel, fitted in the outlet manifold ofthe fired heater.

The flow safety system cuts off the heating when the flow quantity of the thermal fluiddrops below the allowed minimum.At a nominal flow quantity, the pressure difference is 0,3 bar.In order to prevent cracking of the thermal fluid and damage to the fired heater it isnecessary to maintain a minimum flow quantity through the fired heater. Set point 0,25 bar.

When the thermal fluid is cold (lower than 50°C) the viscosity is so high that the minimumflow quantity through the fired heater is not obtained.Under these conditions the min. flow switch is by-passed in combination with the secondcontact of the min. flow switch which is set lower. Set point 0,1 bar.As long as the min. flow quantity through the fired heater is not obtained the burner flameremains in the lowest load position.

B) The economisers

Each economiser is built up from concentric coils. The hot exhaust gases of the engine flowbetween these coils and transfer their heat to the thermal fluid.

Each economiser is provided with two combined exhaust gas valves. These valves arecontrolled by means of a modulating pneumatic cylinder in combination with an electroniccontroller make Wiesloch type 93 W01 701. Set temperature for max load 185°C.When i.e. the temperature of the thermal fluid rises above the set value of the electroniccontroller the exhaust gas valve of the concentric spirals closes and the exhaust gas valveof the external by-pass opens so that more hot exhaust gases passes through the internal by-pass.

Each heater is provided with the following safety devices:- A maximum thermostat make Jumo type ATHs-2.- A flue gas thermostat in the exhaust gas pipe after the heater make Jumo type ATH-7.- A flow safety system consisting of a measuring orifice in accordance with DIN 1952 anddifferential pressure switch type 702 02 100.

When activated, these safety devices cause an alarm in the electric panel of the oilfiredheater and a central alarm in the central switch board.

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When an alarm occurs on the control panel of the economiser, for example:Max. temperature thermal fluid.Max. temperature exhaust gas.Thermal fluid flow insufficient etc.No electric supply.Low level expansion tank.

The exhaust gas valve of the internal by-pass opens so that all the exhaust gases passesthrough the internal by-pass.

In case of a fault in the automatic electronic temperature controller it is possible to controlthe exhaust gas valves by hand.

Each economiser in combination with its electronic controller, pneumatic cylinder and itscombined exhaust gas valves maintains a constant supply temperature to the heatconsumers.The electronic controller is set to a temperature of 185°C for max. load.When the heat consumers require less heat than produced by the economiser, the exhaustgas valve of the internal by-pass opens and less hot gases passes through the concentricspirals.When the heat consumers require more heat than can be produced by the economisers, thefired heater will automatically starts in order to replenish the heat shortage.

As with the fired heater, the minimum quantity of thermal fluid flowing through the heatertubes must be maintained in order to prevent cracking of the thermal fluid and damagingthe heater tubes.During port operation the economisers have to circulate also. This in order to prevent dewpoint corrosion.

Each economiser is provided with one central cleaning nozzle, which is mounted in thebottom part and connected to the water system of the ship.During operation the valve before the nozzle can be opened and the heater will be cleaned.To keep the heat surface of the economiser clean, it is advisable to open this valve once aweek, during 2-3 sec. with intervals of approx. 3 minutes until the economiser is clean.The bottom of the heater is provided with drain connections, which can be connected to apot with a level switch.(leakage device)In case of a leakage the level switch will give an alarm in the control panel of the firedheater. ~

The economiser is also provide with two extinguish nozzles, which are mounted in the topconnection of the heater, and connected to the so called technical water tank of the ship.These nozzles are only to be used in case of fire.

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C) The thermal fluid pumps

The two thermal fluid pumps are connected in such a way as to effectuate automaticswitching on of one pump in case of failure of the other. This changing over takes place atthe command of the minimum pressostat PC. Set pressure: 3,5 Bar.In order to be able to start the pumps automatically, the shut-off valves in the suction anddelivery pipe should be open.The delivery pipelines of the pumps are equipped with non return valves to prevent flowingback of the thermal fluid through the pump which is not in operation.

D) The minimum flow control

The economiser and oilfired thermal fluid heater are provided with flow switches.

It can happen that a lot of the temperature control valves of the heat consumers will be| closed and in that case the flow over the heaters would be insufficient.

To avoid an alarm, a minimum flow control set is installed between supply and return line.The valve will be electrically opened by means of the actuator. The pressure will rise incase the flow is reduced and by opening the valve a constant flow is assured over the oilfired heater and economiser.

The min. flow controller in the system ensure that at all times a min. flow quantity flowsthrough the heaters. Should the quantity passed in the systems be reduced as a result of theclosing of the temperature control valves or hand operated valves of the heat consumers,the pressure before the min. flow controller will rise and the min. flow control valve willopen so far as to maintain the minimum flow through the heaters.

The procedure for adjusting the min. flow controller is as follows: Close down all heatconsumers and adjust the setpoint of the pressure controller of the min. flow equipment in

' such a way that the min. flow quantity flows through the heaters. Each heater has its own' flow indicating switch as a safety guard. The setpoint is at 0,25 bar. At a pressure

difference of 0,4 bar the heater has its nominal flow.

The setpoint of the pressure controller of the min. flow equipment should be adjusting insuch a way that the flow indicating switch of the heater registers a value of approx. 0,4 bar.During commissioning the setpoint of the electric pressure controller is found throughexperience.

The min. flow equipment is equipped with a by-pass line with a manual regulating valve.If the min. flow controller is out of order, the min. flow through the heater has to beregulated as good as possible by means of the by-pass valve following the procedurementioned before.

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E) The expansion tank

The expansion tank, normally being installed at the highest point of the installation isconnected to the system by means of the expansion pipe and the cooling pot.By heating the thermal fluid there will be an increase in volume which will be compensatedthrough the expansion pipe in the expansion tank. Possible vaporisation and volatilecomponents will escape through the de-aeration pot, de-aeration pipes, expansion tank anddrain/collecting tank Into the open air.

A cooling pot is mounted between the de-aeration pot and the expansion tank.The heat supply to the expansion tank as a result of internal circulation in the expansionpipe is blocked by the cooling pot.The thermal fluid in the expansion tank is to be kept as cold as possible. A maximalthermal fluid thermostat make Jumo type ATHs-2 is mounted Set temperature: 50°C.The expansion tank is provided with a magnetic level indicator.On this level indicator one reed contact is mounted for low a level (pre-alarm).The expansion tank is also provided with two level switches one as a switch for low lowlevel and one for high level.The switch for too high a level will block the burner when connected, and the switch forlow low a level will switch off the burner and pumps.There are boiling out pipes between the heaters and the expansion tank. These boiling outpipes are only used during the first starting up and after a long period of stand still. Theyserve to evacuate vapour and volatile components through the expansion tank and thedrain/collecting tank into the open air.Immediately hereafter the boiling out valves should be closed and kept closed, as theageing process of thermal fluid is accelerated by a higher temperature in the expansiontank.

The expansion tank is also provided with an emergency quick opening valve with limitswitch. This valve has to be operated only in case of fire by means of a steel pull cable.This valve must be operated from a safe place.

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IV. General instructions

Thermal fluid should at all times flow through the economisers also in case of portoperation, when the fired heater is only stand-by. This is necessary to prevent corrosion ofsulphur in the economisers.

When thermal fluid has penetrated into the insulation as a result of leakage, it should beremoved at once. This with a view to fire-risk.

It is desirable to have the thermal fluid tested for its quality by the fluid supplier, at leastonce a year.

The boiling out valve(s) is (are) only used during the boiling out process of the system.During operation this (these) shut-off valve(s) should be closed.The thermal fluid in the expansion tank must not get warm, as otherwise an acceleratedageing of the fluid will take place.

When the thermal fluid has cooled to the ambient temperature after the first putting intooperation, all the nuts/bolts of the flanges, fittings and such have to be checked.

After about 2500 hours of operation it is advisable to have the plant checked by one of ourservice engineers.

Before putting the main engine into operation, one of the thermal fluid pumps should berunning. The thermal fluid should always flow through the economisers. If there is no flowthrough the economisers, the temperature of the thermal fluid will rise too high as a resultof the hot exhaust gases and the thermal fluid will start cracking.

When the low level switch is actuated, the pumps and the fired heater will immediately beswitched off. Too low a level might imply a leakage of thermal fluid from the system. Itis imperative to take immediate action in order to eliminate the leakage or to shut off theleaking device.When the pumps are switched off, the flow through the economiser will stop. The power

\ of the main engine has to be reduced to such an extent as to cause a temperature drop of the' exhaust gases to a temperature that is lower than the film temperature of the thermal oil.

Film temperature ca. 320 °C. This temperature depends on the kind of thermal fluid used.

When the high level switch is actuated, the fired heater will be switched off. However thepumps continue their operation.

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4.1 Flue gas thermostat of the fired heater

Actuation of this thermostat may mean that:a) The heater is polluted on the flue gas side,b) The flow of thermal fluid through the boiler has stopped, without functioning of the flowprotection.

4.2 Exhaust gas thermostat of the economiser

Actuation of this thermostat might mean that:a) The heater is polluted on the exhaust gas side,b) The flow of thermal fluid through the heater has fallen out,c) The thermal fluid is leaking and burning,d) One or more exhaust valves of the engine are leaking.

The resistance on the exhaust gas side is too high

An increased resistance on the exhaust gas side may mean that the economiser is polluted.

4.3 Cleaning of the fired heater

A polluted heater should be cleaned with water to which strong alkaline agents are added.By removing the heater cover which is fixed to the heater by means of chain keys, thecombustion chamber, the first and the second drought of the flue gases will be accessiblefor cleaning purposes. The polluted water can be drained from the bottom of the heater.When mounting the cover attention should be paid to the sound condition of the gasketbetween the cover and the heater, and to the uniform tightening of the cover in order toprevent leakage of flue gas.After cleaning, the heater should be brought as soon as possible to the requiredtemperature, this with a view to the possible presence of sulphurous acid.

4.4 Cleaning of an economiser

A polluted economiser should be cleaned with water to which strong alkaline agents areadded.The water jet to be directed between the openings of the concentric coils and, if necessary,clean the pipes with a brush.The polluted water can be drained from the bottom of the heater.During cleaning, attention should be paid to prevent water flowing into the turbo chargerthrough the exhaust gas pipe.After cleaning, the heater should be brought as soon as possible to the requiredtemperature, this with a view to the possible presence of sulphurous acid.For Water washing of the economiser during engine running, see pagel^.

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4.5 Stopping the fired heater

When the fired heater is put out of operation for repairs or cleaning activities, the followingprocedures are to be adhered to:1) Close the shut-off valves before and behind the heater,2) Open the by-pass valve in order to maintain the circulation through the economiser andthe heat consumers.In doing so one should prevent that, owing to the too far opened position of the adjustingvalve, the quantity passed will increase to such an extent as to cause thermal failure of themotor of the thermal fluid pump.

4.6 Stopping the economiser

When, on account of repairs, the economiser has to be stopped, the shut-off valves beforeand after the economiser should be closed, and the by-pass valve be opened. In case ofleakage of thermal fluid, the thermal fluid should also be discharged from the economisernext to the above mentioned procedures.With pressurised nitrogen the thermal fluid can be pressed out of the heater. This procedurewith nitrogen pressure is only applicable to heaters in horizontal execution.

4.7 Adjustment of the control valve in the by-pass piping of the fired heater

The by-pass pipe has a dual purpose:1) To admit part of the quantity of thermal fluid in circulation when the heater is inoperation. This occurs when a larger quantity of thermal fluid is flowing through theeconomiser than through the fired heater.2) To maintain the circulation quantity for the economiser, when the fired heater is out ofoperation.

The position of the control valve should be such as to realise the nominal flow of thermalfluid through the fired heater. The indication of the differential pressure switch of the firedboiler should be 0,4 bar.

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V


4.8 Adjustment of the economiser

The fired heater and the two economisers are connected in series. The two economisers areconnected parallelAt a nominal flow the pressure difference FIA is for:Economiser: 0.4 barBy means of a common control valve or by means of a separate control valve, the before-mentioned value is to be obtained.

4.8.1 Adjustment of the minimum flow controller

The procedure is as follows:1) Shut off all heat consumers,2) The set point is to be adjusted in such a way as to maintain the minimum flow throughthe fired heater and the economisers. (see also the description of the minimum flowequipment)

4.8.2 Adjustment of the heat consumers

The adjustment has a triple purpose:1) To prevent a short circuit (on the flow side),2) To maintain a constant thermal fluid supply temperature to the heat consumers,3) To prevent that the return temperature of the thermal fluid will be lower than 140°C. Atemperature lower than 140°C will bring about sulphurous corrosion in the heater.

The heat consumers, with the exception of the tanks (bunker tanks, lub. oil tanks, and soon) should be adjusted by means of the control valve in the return line, at a temperaturedifference between the supply and return line of 40°C.

The tanks should be adjusted in such a way as to create the possibility to transfer the heatrequired and to prevent the common return temperature to the heater dropping below140°C. The temperature difference between the supply and return temperature is in generalgreater than 40°C.

4.8.3 Adjustment of the control valve in the by-pass pipe of the minimum flow controller

In case the minimum flow controller gets out of order, the control valve of the by-passshould be opened so far as to maintain the minimum flow through the fired heater and theeconomiser, with the heater consumers closed.

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V. Operational instructions of the thermal fluid plant

See flow diagram nr. :D11328Electric diagram nr. : D11343

Boiling out the systemBoiling out implies:The removal of water and gases from the thermal fluid system.Boiling out is necessary:- During the first starting up,- When the installation has stopped for a longer period (more than 4 weeks).

5.1 Open the necessary valves in the circuit.

5.2 Check the level in the expansion vessel - minimum 50 mmto maximum 100 mm above the low level switch LA-LL.

5.3 Check the level of the thermal fluid in the bearings of the two pumps. The bearing of thepump shaft is lubricated with thermal fluid. Check the alignment of the pumps.

5.4 Check the minimum adjusted value of the differential flow switch (FIA).Setpoint 0,25 bar.Check the minimum setpoint of the second control of the same differential flow switch.Setpoint: 0,1 bar (only for starting procedure with a thermal fluid temperature lower than50°C).

5.5 Adjust the partial load of the temperature control at 100°C.Adjust the full load of the temperature control about 10°C lower than the partial load.

5.6 Adjust the maximum thermostat TA of the fired heater at 220°C.

5.7 Adjust the flue gas thermostat of the fired heater at 280°C for the time being.When the fired heater is running at its operational temperature, adjust the flue gasthermostat at a value which is 50°C higher than the measured flue gas temperature.

5.8 Adjust the pressure switch that effectuate the automatic change-over of the pumps whenone had broken down, at 3,5 bar.

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5.9 Adjust the maximum thermostat (thermal fluid side) of the economiser at 220°C.

5.9.1 Check the function of the electronic temperature controller TIC and its pneumatic cylinderof each economiser.

5.9.2 Adjust the electronic temperature controller TIC at 185°C.

5.9.3 Check the function of the electric pressure controller PIC and the electric control valve(min. flow controller).

5.9.4 Adjust the electric pressure controller at 2,4 bar above the static pressure of the system forthe time being. When the plant has reached its operational temperature, adjust the pressurecontroller to the correct value.The procedure is as follows:a) Shut off all heat consumers,b) Adjust the set point in such a way as to maintain the minimum

flow through the fired heater and economisers.

Adjust the extra controller of the electric minimum flow control set for the time being atapprox. 50 °C. After the installation has reached its working temperature adjust the extracontroller at its setpoint of 140 °C. This to prevent dewpoint corrosion in the heaters.

5.9.5 Check the fuel circuit of the burner.

5.9.6 Check the capability of the heat consumers to process the supplied heat.

5.9.7 Switch on the main switch of the fired heater.

5.9.7.1 Switch on the switches of the thermal fluid pumps.

5.9.7.2 Switch on the burner switch.

When necessary release the safety circuit and the automatic device of the burner.

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The burner starts automatically and will stay at its low load position as long as the returntemperature of the thermal fluid is lower than the set point of the inlet minimumthermostat. After that the minimum flow through the heater has been obtained and theburner will switch over to its full load position.The burner has the following sequences of operation: purging the combustion chamber -ignition - operation.Maintain the temperature of the thermal fluid at 100°C for half an hour. Boil out the systemwith the boiling out valves of the fired heater and economiser and expel the air through theexpansion tank and the drain/collecting tank.Also de-aerate with the air relays valves if any.

When no pressure fluctuations are to be seen at the pressure gauges of the pumps and theflow safety device, the temperature is to be raised by approx. 10°C. The adjusted value ofthe temperature control is 110°C.Turn to this temperature for about 15 minutes.When there are no more pressure fluctuations to be seen, raise again the temperature by10°C and run the plant at the new adjusted temperature for about 15 minutes.Repeat these procedures until the desired temperature of 185°C has been reached. Keep thesystem at 185°C until no more pressure fluctuations are to be seen at the pressure gaugesof the pumps and flow safety devices.These temperature gradations and the indicated times are reference values.

Boiling out the system should be done slowly and carefully.If there is water in the system, and the temperature gradations taken are too large,vaporisation may suddenly occur.The vapour pressure pushes the thermal fluid into the expansion tank. When the expansiontank cannot receive this thermal oil, the fluid leaves the expansion tank through the safetyvalve into the drain/ collecting tank, the so-called boiling out.It is necessary to discharge this escaping hot thermal fluid to a safe place, for instance bycollecting this fluid in a drain tank located at a lower level.

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In order to accelerate the boiling out process the heaters and the heat consumers should beboiled out one by one.

Example:One starts with the fired heater and allows the thermal fluid to circulate through theminimum flow controller back to the fired heater. The economisers and heat consumers areshut off (keep only the delivery valve of these devices closed, always keep the valve in thereturn pipe open).Once this circuit has been boiled out, then have one economiser join the circulation. Whenthis circuit has been boiled out, shut off this economiser and boil out the second one thenboil out for instance the circuit of the fired heater and a heat consumer.Once this circuit has been boiled out, than for instance the circuit of the fired heater, bunkertank, minimum flow controller.Repeat this procedure with all the other heat consumers until the entire plant has beenboiled out.

During boiling out the water present in the expansion tank is to be drained.

When possible the filter has to be cleaned when the thermal fluid has cooled down. A filthyfilter can i.a. be ascertained by the reduced differential head and by the reduction of theliquid quantity through the heater (flow meter FIA).

If necessary regularly open the by-pass valves of the fired heater, economiser, minimumflow controller and heat consumers for a moment during boiling out of the system in orderto discharge the present water.

Once the system has been boiled out the boiling out valves should be closed and blocked.

When the system has reached the operational temperature the following components areto be adjusted: See chapter "General".- Adjustment of the by-pass valve of the fired heater.- Adjustment of the economiser.- Adjustment of the minimum flow controller.- Adjustment of the heat consumers.

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Set points of the control devices

Temperature control device of the fired heater:Partial loadFull loadElectronic temperature controller of the economiserMax. load

Set points of the safety devices

Maximum thermostat(s) of the fired heaterMaximum thermostat of the fired heater (pre-alarm)Maximum flue gas thermostat of the fired heater:Flow safety device of the fired heaterPressure switch for the automatic stand-by of thethermal fluid pumpsMaximum thermostat(s) of the economiser(on the side of the thermal oil)Flow safety device of the economiserMaximum exhaust gas thermostat in the exhaust gasesof the engine after the heaterMinimum flow controller of the systemMaximum fuel fluid thermostat for M.D.O.Minimum fuel fluid thermostat for M.D.O.Inlet minimum thermostat (cold start thermostat)Flow safety device of the fired heater for inletminimum thermostat (cold start thermostat)Maximum thermostat expansion tank

190°C185°C

190°C

220°C210°C325°C0,25 bar

3,5 bar

220°C0,25 bar

325°C2,4 bar°C°C50°C

0,1 bar50°C

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VI. Maintenance of the thermal fluid plant

Daily:

Check all the flanges and gaskets for tightness.The flue gases of the fired heater should be colourless.If this is not the case, check the burner and the combustion.Check the level in the expansion tank. Mark the level at the operational temperature on thegauge glass and maintain this as a reference level.Check the correct operation of the photocell.Switch on the burner and cover the photocell.The burner should show a malfunction within 10 seconds.Check the correct operation of the fuel filter.We refer to the enclosed maintenance instructions for the maintenance of the burner andpump.

Weekly:

Check the correct operation of the maximum thermostat(s) and the flue gas thermostat ofthe fired heater.Check the correct operation of the flow safety device FIA of the fired heater, the pressureswitch PC for the automatic stand-by, the switching of the pumps and the flow safetydevice FA of theeconomiser by squeezing the delivery valve between the pump and the fired heater.Drain the water (if any) from the expansion tank.Check the correct operation of the maximum thermostat(s) (on the liquid side) and of theexhaust gas thermostat of the economiser.Check the soot number and the CO2 percentage of the combustion of the fired heater.Check whether the exhaust gases of the fired boiler are free fromCO.Check the correct operation of the temperature and pressure controls in the thermal fluidsystem.Check the correct operation of the pneumatic cylinder and its combined exhaust gas valves(Hand operation on the electronic controller).

Clean the ignition electrodes and the nozzles.Check the distance of the ignition electrodes.For the burner, pump and other equipment we refer to the maintenance instructionsenclosed.

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Every six months:

The time mentioned is a reference value. Maintenance is dependent on i.a. the operationalconditions of the thermal fluid plant and the adjustment of the main auxiliary engine withreference to the exhaust gases.

Check the interior of the fired heater for seat formation and for the sound condition of theinsulation in front and at the rear of the heater.For cleaning procedure see chapter "General".Check the interior of the economiser.For cleaning procedure see chapter "General".Clean the filters in the thermal fluid system.Have the quality of the thermal fluid checked by the fluid supplier.

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VII. Water washing of the economiser

The economiser is provided with a central Water washing nozzle, mounted in the bottomconnection of the heater.To obtain good cleaning results, the wash water should satisfy the following conditions:

The water pressure must be between 2 and 4 bar.The temperature of the water should be between 50°C and 70°C.The water should be Alkaline with a pH value of about 11.When it is not possible to obtain the above mentioned quality of wash water you mayuse fresh water instead.The water connection VT. G must be connected with a quick closing valve.The main engine must run at normal speed.The temperature of the thermal fluid must be minimal 140°C.

In this situation you have to open the quick closing valve for about 5 seconds.This action must be repeated for several times, with intervals of circa 3 minutes, until theeconomiser is clean.As a reference temperature see the temperature of the exhaust gasses after the economiser.(Note: the cleaning time must be established experimental during sailing time.)This repetition depends on the pollution of the heater.The existing temperature in the economiser will change the waterhaze into steam and thissteam will remove the sootblacking.

At a water pressure of ca. 3 bar the capacity of the wash water is ca. 6000 litres/h.

The degree of pollution is determined by the type of fuel and the quality of the combustionin the main engine.

\\POC_AALBORG\Adm_AJgenj«n\MantiaIs\200l\barJOOI9_l<x>20a00 doc page 25

9.2 Regulating system - RL8 to RL11, RMS7 to RMS11

OperationOperational diagram 1During burner shutdown and the prepurge period, the shutoff devices (6), (3) and (7) are closed and shut off device(4) is open.

The ring main pressure during burner shutdown or thepump pressure during prepurge is present at shut offdevices (6) or (7).

Operational diagram 2After the prepurge period has elapsed on RL burners (theservomotor is in ignition position), the shut off devices (6),(3) and (7) open and shut off device (4) closes. The fuel isthen released for combustion.

On RMS burners, shut off devices (6) and (7) only open foroil circulation. After the oil circulation period has elapsed(max. 45 s), shut off device (3) opens and shut off device 4closes and releases the fuel oil for combustion.

The integral pressure switch (17) checks the pressure inthe return. If the pressure increase is too high, the burnershuts down. In shutting down, Shut off devices (6), (3) and(7) close and shut off device (4) opens simultaneously.

RL and RMS burner nozzle head

Attention!The shut off devices (solenoid valves (6) and (7)) areelectrically connected in series. The voltage of thesolenoid coils is therefore 115V with 230 V mains voltage

On the shut off device (solenoid valve) (7), the directionalarrow O on the solenoid valve must point towards thenozzle. This means that the solenoid valve in the nozzlereturn is fitted against the flow direction -^ during burneroperation.

The shut off device in the nozzle head (nozzle shut offvalve) acts as a safety shut off device in the flow and thereturn.

Together with the safety shut off devices (6) and (7) andthe safety shut off device in the nozzle head, therequirement for two shut off devices in both the supply andreturn is fulfilled.

For legend and notes on the wiring and installationdirection of the solenoid valves see chapter 8.

I

Supply control circuit Supply I Closing needle Nozzleplate

Return control circuit Return Regulator nozzle type WSwirlplate

Operational diagram 1 (RL) Operational diagram 2 (RL)

12

18

9.3 Oil meters and oil regulators

Installation of oil meterWhen meters are fitted in the supply and return, the systemmust be protected from excess pressure by a pressurerelief valve installed in the return (see pipeline diagrams inour worksheets).

A blocked return meter can cause the following:

- Bursting of oil hoses- Pump damage (glands on pump leaking).- Changes to the oil flow without changes in combustion

air can occur during burner operation if the meter isblocked. The return pressure which results renders theoil regulator ineffective. Renewed burner start may leadto an explosion.

Isolating elements in the return should be protected fromunintended closing (e.g. ball valves by mechanicalconnection). Non-return valves must not be installed. Withresidual oils all pipework and fittings must be adequatelyheated.

Oil regulator - RL5 to RL11; RMS7 to RMS11The oil regulator is driven by the servomotor. The variableoil throughput is controlled by a V-slot grove.

Each regulator has two regulating groves, which can bechanged. Each regulator has two identification numbersmarked on the shaft, e.g. 00-0 (see illustration).

The slot depths are assigned by both identificationnumbers. The following illustration shows the assignmentto the oil throughput.

Setting example: key on number 00

Oil regulatoridentification number

Useoil throughput kg/h

000

1•2__345

051

71121

281381421

- 50- 70

-120 /- 280

-380-420-700

In order to regulate the oil quantity via the correctmetering slot, the key has to be set to the appropriateidentification number.

If radiated heat affects the nozzle head, the oil regulatorcan be limited in its regulating movement (e.g. to position100, see servomotor). This results in a greater oil spill backwhich cools the sealing ring and pressure spring in thenozzle head.

Primary settingshaft identification No.oil regulating cam

Selected shaft identification No. visible from above

Cam identificatione.g. cam 6

Primary settingregulating cam 1

Shaft key

Full load setting

19




Operational diagram 2After the prepurge period has elapsed on RL burners (theservomotor is in ignition position), the shut off devices (6)T

(3) and (7) open and shut off device (4) closes. The fuel isthen released for combustion.





On the shut off device (solenoid valve) (7), the directionalarrow t> on the solenoid valve must point towards thenozzle. This means that the solenoid valve in the nozzlereturn is fitted against the flow direction - l during burneroperation.




Supply control circuit Supply Closing needle Nozzleplate

Return control circuit Regulator nozzle type WSwirlplate


I I18




- Bursting of oil hoses- Pump damage (glands on pump leaking).- Changes to the oil flow without changes in combustion

air can occur during burner operation if the meter isblocked. The return pressure which results renders theoil regulator ineffective. Renewed burner start may leadto an explosion.








000

r - -

_ .

345

051

71121

281381421

- 50- 70

-120 s- 280/

-380-420-700







Shaft key

Full load setting

19

83040202-1/99Installation and operating instructionsWeishaupt oil burners L, RL, M/MS. RM/RMS,Sizes 5 to 11

weishaupt-

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Contents

Conformity certification

We hereby confirm that Weishaupt oil burners conform tothe basic requirements of the following EU guidelines:

- 98/37/EC Machinery Directive- 89/336/EEC Electromagnetic Compatibility- 73/23/EEC Low Voltage Directive

Therefore the burner carries the CE Label.

Extensive quality assurance is guaranteed by a certifiedQuality Management System to DIN ISO 9001.

Max Weishaupt GmbHBurner and Heating SystemsD-88475 Schwendi

1. General instructions 4

2. Burner installation 5

3. Oil supply 6

4. Installation instructions for metallic oil hoses 8

5. Oil preheating system 105.1 Preheaters 105.2 Heated components 10

6. Oil pumps 12

7. Attaching the fan 1 4

8. Burner fuel systems 1 5

9. Regulating systems 179.1 Regulating system -RL5 and RL7 17 179.2 Regulating system - RL8 to RL1 1 ,

RMS7toRMS11 189.3 Oil meters and oil regulators 1 9

1 0. Nozzle recirculation on MS burners 20

11. Capacity graphs 2311.1 Capacity graphs

for burner types Land RL 231 1 .2 Capacity graphs

for burners type M/MS and RM/RMS 29

1 2. Nozzle selection 331 2.1 Two and three stage burners 331 2.2 Sliding two stage and modulating burners 35

1 3. Adjustment of the combustion head 37

1 4. Ignition electrode setting 39

1 5. Air regulation, two and three stage burners 4015.1 Description of functions for

servomotor type 1 055 421 5.2 Setting the cam's limit and auxiliary

switches on servomotor type 1 055 43

1 6.Oil/air compound regulation, sliding two stageand modulating burners 441 6.1 Setting the cam's limit and auxiliary

switches on servomotor type SQM 45

17. Commissioning 4617.1 Checks prior to first commissioning 4617.2 Setting 46

1 S.Sequence of operations 4818.1 Prerequisites for burner start 481 8.2 Symbols on the lockout indicator 491 8.3 Basic wiring diagram for

LAL2/LOK16... burner controllers 501 8.4 Switching times 521 8.5 Technical data 52

19. Fault conditions and procedures 53

1. General instructions

SafetyTo ensure safe burner operation, the burner has to beinstalled and commissioned by qualified personneland all guidelines in these operating instructions haveto be followed.

In particular, attention must be paid to relevantinstallation and safety requirements (e.g. DIN, VDE).

Flame monitoring devices, limit controls, correctingelements and all other safety devices may only becommissioned by the manufacturer or their authorisedagent.

Failure to comply can lead to serious injury or deathand can cause considerable damage to the plant.

Qualified personnelQualified personnel according to this operatingmanual are persons who are familiar with theinstallation, mounting, setting and commissioning ofthe product and who have the necessary qualificationssuch as:-

- Persons who are trained to operate electricalcircuits and units to the safety standards given andare qualified to earth and mark these.

Operating instructionsThe operating instructions included with each burner mustbe displayed clearly in the boiler room. In conjunction withthis we refer to DIN 4755, Point 5. The address of thenearest service centre must be entered on the reverse sideof the operating instructions.

Instruction of personnelProblems are often caused by incorrect burner operation.The operating staff should be thoroughly instructed withregard to the operation of the burner. With frequentlyoccurring burner faults, the nearest service centre must benotified.

InstallationThe installation of oil fired plant must be carried out inaccordance with extensive guidelines and regulations. It isthe duty of the installer to familiarise her/himself with allregulations. Installation, commissioning and maintenancemust be carried out with care. Fuel oils used must complywith DIN 51 603.

Electrical wiring diagramA detailed electrical wiring diagram is included in everyburner delivery.

Maintenance and serviceIn accordance with DIN 4755, the whole installationincluding the burner should be inspected once a year by arepresentative of the manufacturer or a competent andqualified person. The combustion figures should bechecked after every service and each time a fault has beenrectified.

Ambient requirementsThe burners material, construction and type of protection isdesigned for use indoors. The permissible ambienttemperature is -15°C to +40°C.

Electrical installationWhen installing the electrical connection cables ensurethat these are long enough to allow the burner and boilerdoor to be hinged open.

Control circuits, which are taken from one of the supplyphases, must only be connected with an earthed neutralconductor.

On an unearthed mains supply, the control voltage must besupplied via an isolating transformer.

The pole of the transformer that is to be used as aneutral conductor must be earthed.

The control circuit phase and neutral conductors mustbe connected correctly.

Ensure the correct fuse ratings are not exceeded. Earthingand neutral conductors must conform to local regulations.

2. Burner installation

The drawing is an example of refractory for a heating• appliance without cooled front. The refractory must not

L extend beyond the front edge of the combustion head(dimension I,). The refractory may, however, take a conicalshape from the combustion head front edge (> 60°).Refractory may not be required on boilers with watercooled fronts, depending on the boiler manufacturersinstructions.

The boiler front plate must be prepared in accordance withthe above dimensions. The burner hinged flange can beused as a template for the drilling. The threads of the boltsand tappings must be coated with graphite prior to fitting.

Example for burners with head extension see page 13.

Mounting the burner on the heat exchanger

Example of installation on aheating appliance with refractory

Sizes5-10

Size11

The gap between combustion head and refractory mustbe filled with flexible insulating material. Do not makesolid.

Burnersize

55

77

888/28/28/2

91011

Combustion Dimensions in mmhead type di d2

M5/1aM5/2a

M6/1aM7/1a

M7/1aM8/1aM9/1aU2/1G7/2a

M9/1aM10/2M11/1

180160

200220

220240240220265

240265325

M10M10

M10M10

M10M10M12M12M12

M12M12M10

d3

210210

235235

235235298298298

330330400

d4

185185

210210

210210275275275

278278340

ds

220190

240260

260280280260300

280300365

\! Combustion headopen closed

145130

216226

226236226229264

225268362

154144

228238

238248251239270

240

Hinged flangeThe burner can be hinged to the left or right depending onthe position of the hinge pin and by releasing the lockingnut.

Limit switchThe limit switch is arranged so that the electrical circuit isclosed when the burner is hinged closed. The circuit isbroken by the release of the tripping pin in the limit switchas the burner is hinged open.

Locking nut

Oil hose connection according to burner type

Oil hoses

L5ZL5TL7ZL8ZL8Z/2L9Z

L7TL8TL8T/2L9TL10T

RL5RL7RL8RL8/2RL9RL10RL11

M5ZMS7ZMS8ZMS8Z/2MS9Z

RMS7RMS8RMS8/2RMS9RMS10RMS11

DN

131313131313

1313131313

13202020202025

1320202020

202020202025

Length mm

Supply

100010001000100010001000

10001000100010001000

1000100010001000100010001300

10001300130013001300

130013001300130013001500

Return

100010001000100010001000

10001000100010001000

1000100010001000100010001300

7001000100010001000

100010001000100010001300

Connectionthreadpump side

R1/2"R1/2"R1/2"R1/2"R1/2"R1/2"

R1/2"R1/2"R1/2"R1/2"M 30x1. 5

R1/2"M 30x1. 5M 30x1. 5M 30x1. 5M 30x1. 5M 30x1. 5M 38x1 . 5

R1/2"M 30x1. 5M 30x1 . 5M 30x1. 5M 30x1. 5

M 30x1. 5M30x1.5M 30x1. 5M 30x1. 5M 30x1. 5M 30x1 . 5

Connectionthreadinstallation side

R1/2"R1/2"R1/2"R 1 /2"R1/2"R1/2"

R1/2"R1/2"R1/2"R1/2"R1/2"

R 1 /2"R1"R1"R1"R1"R1"R1"

R1/2"R1"R1"R1"R1"

R1"R1"R1"R1"R1"R1"

4. Installation instructions for metallic oil hoses (residual oil S)

GeneralThe oil and pressure hoses used are of corrugated highgrade steel with a high grade woven wire sleeve cover.

The oil hoses and pressure hoses are well suited forresidual oil operation if the following application rules areobserved. Resistance against the chemical effects andtemperature of the fuel oil is designed for long termservice.

The new TRD 411, DIN 4787 and DIN 4755 standardsspecify metallic hoses for residual oil installations.

Oil and pressure hoses must be protected from externalmechanical damage. When installing care must be takenthat the hose is not twisted. It must not receive torsionstrain either during installation or during later movement. Itis important that the two hose ends and the movementlie at one level.

In order to guarantee torsion free installation, the hoseshould first be only loosely fixed at one end, then movedthrough the required hose movement 2 to 3 times so thatthe hose can a\\gn without distortion, and only then betightened in position.

It is important to use a second spanner to counter holdwhen tightening.

Care should be taken that the hoses do not come intocontact with each other or other equipment (burner, oillines or boiler) during operation.

Adequate curve radii and minimum hose lengths must beadhered to during installation. In addition the hose must inmost cases be supported when installed horizontally.

The hose connection can be installed for either burnerhinge direction as required.

Example

Use second spanner for counter holding

Connect hose without twisting

Specifications and technical data

Oil hoses in oil supply installations (flow and return)

On installations using residual oil S the hoses must besuitable for an operation pressure of 10 bar and anoperating temperature (medium) of 160°C.

When allowing for the temperature factor for high gradesteel the following applies for these hoses:

Nominal pressure.Test pressureOperating pressureOperating temperature

_PN = 16 bar_PP = 21 bar_PT=10bar

TT = 160°C

When installing the oil hoses in the flow and return(between pump and rigid pipe installation) the productrelated technical drawings should be observed.

For oil EL, oil hoses to DIN EN ISO 6806 are supplied.

Technical data:

Nominal pressureTest pressureOperating temperature

PN = 10bar_PP=15bar

TT = 70° C

Pressure hoses (between pump and nozzle)

For this application the pressure hose should be suitablefor an operating pressure of 30 bar and an operatingtemperature of 160°C.

When allowing for the temperature factor the followingapplies:

Nominal pressureTest pressureOperating pressureOperating temperature

PN = 64 bar_PP = 82 bar_PT = 30barTT=160°C

The minimum curve radius of the hose depends on thenominal clearance on the application, the material and thetype of manufacture.

The hose application on our products has been agreedwith the manufacturer, using original parts.

For free usage and installation, the following minimum radiimust be adhered to as given in the installation instructions.

Minimum radii

DN

68

10

12162025

r = Minimumcurve radius in mm

70100110

110210240250

\

1i i \

2

Hoses should be selected of sufficient length. Anadditional length must be allowed for on the hose ends.This length must remain straight, i.e. the curve radius mustnot commence until after this straight section.

Additional length

DN Z = Additional length in mm

When installation has been carried out the minimum radiimust be checked in the most adverse position. Ifnecessary a fixed stop must be fitted on site to limit themovement.

6810

12162025

808590

100125130135

The minimum curve radius of the hose depends on thenominal clearance on the application, the material and thetype of manufacture.

The hose application on our products has been agreedwith the manufacturer, using original parts.

For free usage and installation, the following minimum radiimust be adhered to as given in the installation instructions.

Minimum radii

DN

68

10

12162025

r = Minimumcurve radius in mm

70100110

110210240250

Hoses should be selected of sufficient length. Anadditional length must be allowed for on the hose ends.This length must remain straight, i.e. the curve radius mustnot commence until after this straight section.

Additional length

DN Z = Additional length in mm

When installation has been carried out the minimum radiimust be checked in the most adverse position. Ifnecessary a fixed stop must be fitted on site to limit themovement.

6810

808590

12162025

100125130135

5.1 Preheaters

The oil can be heated electrically or with a heating medium,or by a combination of both electrical and media preheater.Hot water, low pressure steam, high pressure steam orthermal fluid can be used as heating media.

On installations with a media preheater and withoutelectrical preheater, the following minimum pressures andtemperatures are required for heating the residual oil S:

High pressure steam over 7.5 barHot water from 180 - 200° CThermal fluid from 200 - 300° C

These temperatures and pressures must always beavailable so that the oil can be heated to the temperatureand viscosity required for atomisation.

The ball valve fitted between the media and electricalpreheater (see technical description of electrical andmedia preheaters) is closed when the heating medium isavailable. The valve must only be open during start up on acold plant and remain open until the final workingtemperature or pressure of the installation is reached.During this period only the electric preheater heats the oiland the throughput of the burner must be adapted to thepreheat capacity of the electrical preheater during thestarting time of the cold plant.

On downward firing burners, media preheaters are rotatedthrough 90°C. The oil preheaters MV9 and MV10 can onlybe fitted with the media outlet on top for liquid media orbelow when using steam. If the burner is ordered fordownward firing, this is already allowed for. If the burner tobe changed to downward firing at a later stage, then extrabrackets are required to fix the media preheater.

Cj>.2 Heated components

/ All burners have nozzle head heating controlled by an NTC/ sensor. The ROB regulating control can be set to 65° or[ 130°C and is pre-set to 65°C for delivery. The heatingI elements in the burner are usually controlled by the burner\^pperating switch.

Pump heatingWhen oil viscosities of 152 mmVs at 50°C are exceeded,we recommend heating the pump. Pumps are always fittedwith heating facilities. On type E pumps the gearing coverhas a pocket for the heating element, and if required, theelement can thus be fitted. TA pumps are fitted with

heating elements in the pump body as standard. Heatingallows the oil to be kept in a pumpable condition and thepump to be protected from damage. The heatingcartridges in the nozzle head and pump are active as longas the burner operating switch is on.

Burner heating elementsHeat rating in WBurnertype

M5ZMS7ZMS8ZMS8Z/2MS9Z

**~~~*^.RMS7J"RMSBRMS9RMS10RMS11

Burnerpump type

E4E6E7E7/TA2E7/TA2

TA2TA3TA3TA3TA4

Heating

80808080/10080/100

100100100100100

Nozzlehead

100100100100100

100100100100100

Solenoid valveflow/return

2020202020

2020202020

Valveblock

2020202020

2020202020

Oilregulator

----

2020202020

Pressureregulator

20202020

2020202020

10









On the shut off device (solenoid valve) (7), the directionalarrow D> on the solenoid valve must point towards thenozzle. This means that the solenoid valve in the nozzlereturn is fitted against the flow direction -^ during burneroperation.




Supply control circuit Supplyl Closing needle

Regulator nozzle type WReturn control circuit


18

... •'*" -




Bursting of oil hosesPump damage (glands on pump leaking).Changes to the oil flow without changes in combustionair can occur during burner operation if the meter isblocked. The return pressure which results renders theoil regulator ineffective. Renewed burner start may leadto an explosion.








000

12

45

51

71121

281381421

- 50- 70

- 120-280

-380-420-700







Shaft key

Full load setting

19

83040202-1/99Installation and operating instructionsWeishaupt oil burners L, RL, M/MS. RM/RMS,Sizes 5 to 11

weishaupt

2. Burner installation

The drawing is an example of refractory for a heatingappliance without cooled front. The refractory must notextend beyond the front edge of the combustion head(dimension I,). The refractory may, however, take a conicalshape from the combustion head front edge (> 60°).Refractory may not be required on boilers with watercooled fronts, depending on the boiler manufacturersinstructions.

The boiler front plate must be prepared in accordance withthe above dimensions. The burner hinged flange can beused as a template for the drilling. The threads of the boltsand tappings must be coated with graphite prior to fitting.

Example for burners with head extension see page 13.

Mounting the burner on the heat exchanger

Example of installation on aheating appliance with refractory

Sizes

The gap between combustion head and refractory mustbe filled with flexible insulating material. Do not makesolid.

Burnersize

55

77

888/28/28/2

91011

Combustion Dimensions in mmhead type di d2

M5/1aM5/2a

M6/1aM7/1a

M7/1aM8/1aM9/1aU2/1G7/2a

M9/1aM10/2M11/1

180160

200220

220240240220265

240265325

M10M10

M10M10

M10M10M12M12M12

M12M12M10

da

210210

235235

235235298298298

330330400

d4

185185

210210

210210275275275

278278340

ds

220190

240260

260280280260300

280300365

I, Combustion headopen closed

145130

216226

226236226229264

225268362

154144

228238

238248251239270

240

Hinged flangeThe burner can be hinged to the left or right depending onthe position of the hinge pin and by releasing the lockingnut.

Limit switchThe limit switch is arranged so that the electrical circuit isclosed when the burner is hinged closed. The circuit isbroken by the release of the tripping pin in the limit switchas the burner is hinged open.

Locking nut Hinge pin

Nozzle head heating M5Z to MS9Z Nozzle head heating(RMSfy)o RMS1;

Heating cartridge

Valve block heating M5Z to MS9Z

Heating cartridge

Pump heating M5Z to MS9Z

Heatingcartridge

Solenoid valve flow and return M5Z to MS9Z,(RMS7} toRMS11

Heating cartridge

NIC sensor

Heating cartridge

Valve block heatin^RMS7}to RMS11

Heatingcartridge

Pump heating foMSTFto RMS11 \(

ctt

Heatingcartridge

"" \O/7 regulator(RMS7}to RMS11

Heating cartridge

-, r ,. >, t ; V t •

г V'-O. /'Г "'?

11

6. Oil pumps

The pumps are supplied suitable for connection in a twopipe oil system.

Pumps are supplied with pressure regulating and shut offvalves. The pressure regulating valves keep the pressureconstant.

Adjustment• The oil line on the suction side must be primed and the

pump vented prior to commissioning, otherwise thepump will be damaged due to running dry.

• Insert gauge to check the vacuum or supply or ringmain pressure on the suction side of the pump.

• A pressure gauge must be connected into tapping (5)to measure the pump pressure.

• To adjust the oil pressure, remove cap nut (4) and setthe required pressure.

,i Clockwise rotation = pressure increaseAnticlockwise rotation = pressure decrease

• The suction resistance should not exceed 0.4 bar.

Max. supply pressure on pump type Jon pumps types E and ТА(measured at the pump).

Maximum oil supply temperatureon pumps type E and ТА

. 2.0 bar5.0 bar

90°C

Filter for J and E pumpsA filter is incorporated in the pump to protect the pumpgears.

There are two different types of filters. The filter for Epumps has a large mesh.

The pump filter will require cleaning from time to time,depending on the degree of fouling. With a highjjegree offouling, the vacuum on the suction side increases. Toremove the filter for cleaning, extract the eight screws (12)on the pump cover.

After replacing the filter ensure that the pump cover istightly sealed.

Single pipe operationIn some instances when operating with oil EL, J and ТАpumps can be used with one pipe systems.

The following should be noted:

As there is no suction lift by the pump in a single pipesystem, the oil supply must have a guaranteed positivehead at the pump inlet.

The bypass plug in the pump should be removed and thepump return connection plugged.

The supply line should always be vented whencommissioning.

As it is not possible to vent via the pump return on singlepipe installations, the supply line must in this instance befully vented when commissioning.

Pump couplingA flexible coupling is fitted between fan rotor and pump.

When adjusting the intermediate coupling ensure thatthere is no axial tension on the pump drive shaft.

The coupling element on the pump should have an axialmovement of 1.5 mm.

12

Pump coupling Pump J6 + J7

8

Pump E4, E6, E7

10 11

6 7 4 5 2 2 a 3 1 2

Legend1 Suction connection2 Return connection2a Spill back connection3 Nozzle supply line4 Pressure adjusting screw5 Pressure gauge connection6 Vacuum gauge connection

1 6 7 4 2 5 3 1 2

PumptiA2\TA3, TA4

'• '?» •" ; - ^ С < Л

1 7 4 6 2 5 2a 3 ^ ; ч!> '''

7 Locking screw8 Intermediate coupling piece9 Axial movement 1.5 mm10 Socket head screw11 Pump coupling12 Cover screw

13

'""*'*_;*::

7. Attaching the fan

Attaching the fan Removing the fan

Burner size 5The fan fits onto a cylindrical shaft. A key on the shafttransmits the power. The fan is secured to the motor shaftby an Мб х 25 screw with washer.

Burner sizes 7-8 and 9-11On burners size 7 to 8 the fan fits onto the cylindrical shaft.A key on the shaft transmits the power. The fan is securedto the motor shaft by an M8 countersunk screw andwasher.

On burners size 9 to 11 the fan fits onto a cone shaft. Theself locking cone transmits the power to the motor fan. Thecoupling piece is connected to the fan cylindrical pins. Forsecurity, the coupling piece is connected to the motorshaft by an M10 x 40 screw with left hand thread.

Burners sizes 5 and 7 - 8The extractor part No. 111 111 0001 /2 can be applied tothe two M6 threaded holes and the fan removed.

Burners sizes 9-11To remove the fan, the extractor part No. 121 362 0013/2is applied to the two M10 threaded screws.

Burner size 5 Burner sizes 7 - 8 Burner sizes 9-11

14

8. Burner fuel systems

L5Z L7ZtoL9Z

О

L5T L7TtoL10T

RL5toRL7

115V

115V

5 17

10

115V

CK115V

15

RL8toRL11

14

[ЖЗ—I

Q

115V

IP

EJ

h-J

^^

1

7 17 15 4

• Burner types RL5 to RL7The two solenoid valves (3) are electrically connected inseries. Solenoid valves (3) and (5) are fitted in the returnline against the flow direction.

Burner types RL8 to RL11Solenoid valve (6) in the supply and (7) in the return areelectrically connected in series. Solenoid valve (7) isfitted in the return line against the flow direction.

15

M5Z MS7Z to MS9Z

5 16 11

:ЧН~

17

14 6 16 18 3 13 12

Burner types M5Z, MS7Z to MS9Z, RMS 7 toRMS11Solenoid valve (5) / (6) in the supply and (5) / (7) in thereturn are electrically connected in series. Solenoidvalve (5) / (7) is fitted in the return line against the flowdirection.

17 15

1 Pump without integral solenoid valve2 Solenoid valve type 121C2323 9 W coil

(normally closed) Rp 1 /8*3 Solenoid valve type 121K2421 19 W coil

(normally closed) Rp 1 /8*4 Solenoid valve type 122K9321 19Wcoil

(normally open) Rp 1/8*5 Solenoid valve type 1 21K6220 20 W coil

(normally closed) Rp 1 /4*6 Solenoid valve type 321H2322 20 W coil

(normally closed) Rp 3/8*7 Solenoid valve type 121G2320 20 W coil

(normally closed) Rp 3/8*8 Two stage EL nozzle head

(without integral shut off device)9 Three stage EL nozzle head

(without integral shut off device)10 Nozzle head R (without integral shut off device)11 Two stage nozzle head M (with integral shut off device)12 Nozzle head R (with integral shut off device) in flow and

return13 Restricting orifice14 Filter15 Oil regulator16 Oil preheater17 Pressure switch 0 1 0 bar (set to 5 bar for EL

Return set to 7 bar for MS)18 Thermostat

* Rp = Whitworth pipe thread (internal) DIN 2999

The given voltages refer to 230 V. For 115V controlvoltage, 115V and 55 V devices are used.

16

9. Regulating systems

9.1 Regulating system - RL5 and RL7

The oil system is not fitted with a nozzle shut off valve.The solenoid valves control the oil shut off function.

OperationDuring prepurge solenoid valves (3) and (5) are closed. Oilis supplied under pressure by the pump to the closedsolenoid valve in the supply (5). Solenoid valves (3) and (5)are electrically connected in series.

Operational diagram 1After the prepurge period has elapsed, solenoid valves (3)and (5) open. Oil flows to the nozzle via the nozzle supplyand to the oil regulator (15) via the return. The oil regulatoris in the open position (ignition load position). Due to thelower return flow pressure, less oil leaves the nozzle. Thegreater proportion of oil flows via the nozzle return to the oilregulator or the pump return line. The return flow pressureis approx. 8 bar at partial load position. The integral oilpressure switch (17) shuts down the plant if the pressureis too high.

Operational diagram 2Full load is obtained by reducing the metering slot in the oilregulator. This is done rotation of the oil regulator(clockwise as viewed from the shaft). This throttles the flowof oil in the return and the oil quantity increases at thenozzle outlet. On shutdown the solenoid valves close andshut off the flow of oil to the nozzle and from the oil supply.

For legend and notes on the wiring and installationdirection of the solenoid valves see Chapter 8

RL5 and RL7 nozzle head

Nozzle flow Regulating nozzle

P TT^ Цм£ит»||С

Hi

Nozzle return

Operational diagram 1 Operational diagram 2

( 9.2 Regulating system - RL8 to RL11 i'R*M$} to RMS11, '"- ^OperationOperational diagram 1During burner shutdown and the prepurge period, the shutoff devices (6), (3) and (7) are closed and shut off device(4) is open.







On the shut off device (solenoid valve) (7), the directionalarrow [> on the solenoid valve must point towards thenozzle. This means that the solenoid valve in the nozzlereturn is fitted against the flow direction -^ during burneroperation.




Supply control circuit Supply! Closing needle

Return control circuit Regulator nozzle type W plate


12

* t18

10. Nozzle recirculation on MS burners

Nozzle recirculation on two stage MS burnersAfter the minimum temperature has been reached by thethermal switch contact in the ROB regulating control andoil preheater, burner start is released. The two switches areswitched in series. The oil pump circulates the oil via filterand solenoid valve to the oil preheater, the oil is heated andthe viscosity reduced.

The heated oil forces the oil in the supply system throughthe burner supply, nozzle head, the normally open solenoidvalve 1 to the pump return. Hot oil is now presentthroughout the whole system. The shut off device in thenozzle head remains closed and oil cannot flow throughthe nozzle.

Various burner components are also heated by a heatingcartridge (see chapter 5.1).

After termination of the pre-purge period, the solenoidvalve (3) in the nozzle return is energised and closes. Theoil pressure increases in the nozzle shut off valve and at apressure of approx. 12 bar the nozzle shut off valve opensto commence stage 1 operation.

After a delay the solenoid valve (2) for stage 2 is openedby the burner control. Oil pressure is applied to the nozzleshut off valve which opens stage 2. Nozzle dribble islargely prevented by the secure closure of both nozzles.

Nozzle head heatingHeating takes place directly in the nozzle head which isinsulated. A heating cartridge with a 100 W capacity isfitted in the nozzle body. The nozzle temperature iscontrolled by an electronic P type controller. The sensor isfitted adjacent to the oil line inlet. The ROB control can beset to a temperature of 65C or 130C according to the fuelquality (Factory pre-set 65C).

When the burner shuts down solenoid valve (3) is de-energised and opens. The atomising pressure reducesimmediately and the nozzle shut off valves close.

Nozzle head maintenance and cleaningBoth nozzles can be replaced without affecting thefunction of the hydraulic nozzle shut off valves.If the nozzle shut off valves 1 or 2 are removed, theisolating device in the oil supply and return must first beclosed.

<N.ozzle head heating ot\RMS7 jto RMS 11 burnersAs with two stage burners, regulating burners for residualoils are also fitted with temperature controlled nozzle headheating. This enables the nozzle head to be kept at aconstant temperature. The heating cartridge, whosethermal output is controlled by the ROB regulating control,has a 100 W capacity. The ROB control can be set to atemperature of 65°C or 130°C. The factory pre-set is65°C.

An NTC sensor is fitted on the heating cartridge support tomeasure the temperature.

The temperature release switch in the regulating control isconnected in series with the oil preheater releasethermostat and only allows burner start after the selectednozzle head temperature and minimum oil preheatertemperature has been reached.

Duse 1

Duse2

19 W coil

20 W coil

20 W coil

20 W coil

1 Pump without integral solenoid valve2 Solenoid valve type 121K2421 19 W coil

(normally closed) Rp 1 /83 Solenoid valve type 122K2321

(normally open) Rp 1/84 Solenoid valve type 121K6220

(normally closed) Rp 1 /45 Solenoid valve type 321H2322

(normally closed) Rp 3/86 Solenoid valve type 121G2320

(normally closed) Rp 3/87 Nozzle head as shut off device8 Filter9 Oil preheater10 Pressure switch 010 bar

(set to 5 bar for EL, set to 7 bar for MS)11 Thermostat Solenoid valves (4) / (6) in12 Heat insulation the return are fitted13 Heating cartridge against the direction of14 Nozzle shut off valve flow.

20

Cold start with 2 purge times

V;

оо

о

фСЛ

120

100

Safety valve open _ Safety valve closed

Time [ s ]

Start in warm conditions with oil line temperature in supply > 60°C

V-

oЪоф

СЛ

120

100

А Pre-purge

Time [ s ]

21

Additional start circuit with two purge times for RMS7to RMS11 burners, DIN 4787OperationAfter prepurge has taken place and the ignition positionhas been reached, the safety valves are opened for 35 s toenable the burner fuel system components to be heated.The safety solenoid valves are then closed for approx. 40s. In the meantime the oil preheater will regain heat andcan give the maximum temperature after the 40 s haveelapsed.

After this period the safety solenoid valves are re-openedand at the same time a return signal is given to the burnercontrol to continue the start up sequence. An interval,determined by the burner controller, of about 6 s producesa second purge time up to the oil release where thetemperature peak of the oil preheater is utilised for themoment of ignition.

So that the cold start process does not take place whenstarting from warm conditions or after a short shut downperiod, a thermostat fitted in the burner fuel line systembetween oil preheater outlet and distribution piecedetermines whether it is a cold start or a warm start withshort purge period. The thermostat switching point isapprox. 55 - 60°C. If the oil line temperature is more thanthis figure before the boiler regulator switches on, thenonly the short purge time of 6 s is used for the subsequentburner start. This monitoring assures that there will be nounnecessary delays during the start process.

The circuit is designed in such as way that there is a ballasteffect as far as the switching condition of the thermostat isconcerned. This means that once start up has begun, anythermostat response will not produce an alteration in thesequence of operations, so that either a cold or a warmstart always clearly takes place.

If the oil temperature stipulates a warm start, the start uptime of the burner is shortened by 45 s, the time usuallyused as the delay period.

The circulation return is always fitted into the pump return.

Nozzle heads are tested safety devices and accordingto DIN 4787 must not be interfered with.

22

11. Capacity graphs

11.1 Burner types L and RL

Fig. l

0-10

Fig. II

d

0- 10

d _ —4

-»-

«* I •»-

[

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tH

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0-10 0-10

Important information relating to capacity chartsThe capacity charts show the oil throughput relative to thecombustion chamber pressure. They are maximum valuesmeasured on idealised test flame tubes to DIN 4787.

All ratings data given relate to an air temperature of20°C and an installation elevation of 500 m.

Size 5

Dimensions mmNo. Combustion head Fig.

(1) + (2) M5/2a-1 25x40 IIM5/1a-1 25x40 IIM5/1 a- 145x40 II

506565

160180180

mbar Burner types L5Z, L5TComb, head M5/2a-125x40 M5/1a- 145x40 M5/1a-125x40Rating kg/h 15-68 18-77 26-100

kW 180-810 215-915 310-1190

kW 0 400 BOO 1000 1200

(2)mbar Burner types RL5

Comb, head M5/2a-125x40 M5/1a-145x40 M5/1a-125x40Ratingkg/h 15-70 16-79 25-100

kW 180-835 190-940 300-1190

kW 0 600 800 1000 120

Size?

Dimensions mmNo. Combustion head Fig

(1) M6/1a-1 5 5 x 5 0 IIM7/1a-1 55x50 II

(2) M6/1 a-165x50 IIM7/1a-1 6 5 x 5 0 II

(3) M6/1a-1 75x50 IIM7/1a-1 7 5 x 5 0 II

I d No. Combustion head Fig. I d

90 200 (4) M6/1a-1 5 5 x 5 0 II 90 20090 200 M7/1a-1 55x50 II 90 200

90 200 (5) M6/1a-1 65x50 II 90 200100 220 M7/1a-1 65x50 II 100 220

90 200 (6) M6/1a-1 7 5 x 5 0 II 90 200100 220 M7/1a-1 7 5 x 5 0 II 100 220

mbar

12 -

в

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2kW 2

Burner typesComb, headRating kg/h

kW

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r

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L7Z, L7T mbarM6/1a- 155x50 M7/1a- 155x5041-150 55-165490-1785 655-1965

//

00 400 600

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BOO 1000 1200

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kW 500 - 1 845 655 - 1 965

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1400 1600 1800 2000 kw 200 400 600 800 1000 1200 1400 1600 1800 20C

kg/h

mbar

(2)Burner types L7Z, L7T mbarComb, head M6/1a- 165x50 M7/1a- 165x50Rating kg/h 34 - 1 20 52 - 1 65

kW 405-1430 620-1965

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kW 405-1535 570-1965

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kW 200 400 600 800 1000 1200 1400 1600 1800 2000 kW 200 400 600 800 1000 1200 1400 1600 1800 200

(3) (6)mbar Burner types 172, L7T

Comb, head M6/1 a - 1 75x50 M7/1 a - 1 75x50Rating kg/h 27 - 1 05 50 - 1 60

kW 320- 1250 595-1905

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kW 200 400 600 800 1 000 1 200 1 400 1 600 1 800 200

mbar Burner types RL7Comb, head Мб/1 а- 175x50 M7/1a- 175x50Rating kg/h 27-110 48-165

kW 320-1310 570-1965

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kW 200 400 600 800 1000 1200 1400 1600 1800 2000

24

SizeS

Dimensions mmNo. Combustion head Fig. 1 d No. Combustion head Fig. 1

(1) M7/1a-1 5 5 x 5 0 II 100 220 (4) M7/1a-1 55x50 II 100 220M8/1a-1 5 5 x 5 0 II 110 240 M8/1a-1 55x50 II 110 240

(2) M7/1a-1 6 5 x 5 0 II 100 220 (5) M7/1a-1 65x50 II 100 220M8/1a-1 6 5 x 5 0 II 110 240 M8/1a-1 65x50 II 110 240

(3) M7/1a-1 7 5 x 5 0 II 100 220 (6) M7/1a-1 7 5 x 5 0 II 100 220M8/1a-1 7 5 x 5 0 II 110 240 M8/1a-1 7 5 x 5 0 II 110 240

mbar

(1)Burner types L8Z, L8T mbarComb, head M7/1a- 155x50 M8/1a- 155x50Rating kg/h 57 - 1 95 70 - 230

kW 680 - 2320 835 - 2740

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(2)Burner types L8Z, L8T mbarComb, head M7/1a- 165x50 M8/1a- 165x50Rating kg/h 53-181 65-220

kW 630-2155 775-2620

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(3)Burner types L8Z, L8T mbarComb, head M7/1a- 175x50 M8/1 a -175x50Rating kg/h 50-166 60-197

kW 595-1975 715-2345

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(4Burner types RL8Comb, head M7/1a- 155x50 M8/1a- 155x50Rating kg/h 51-210 65-230

kW 605 - 2500 775 - 2740

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(5Burner types RL8Comb, head M7/1a- 165x50 M8/1a- 165x50Rating kg/h 50-190 63-225

kW 595 - 2265 750 - 2680

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30 1000 1500 2000 2500 300

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Burner types RL8Comb, head M7/1a- 175x50 M8/1a- 175x50Rating kg/h 50-169 57-210

kW 595-2015 680-2500

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00 1000 1500 2000 2500 3000 KW 500 1000 1500 2000 2500 30C

25

Sizes 8/2

Dimensions mmNo. Combustion head Fig. 1 d No. Combustion head Fig.

(1+5) M9/1a-1 65x50 III 90 240 (4) U2/1 -165x50 IM9/1a-1 85x50 III 90 240 G7/2a-1 65x50 II

(2) U2/1 -145x40 I 85 220 (6)

(3) U2/1 -155x50 I 85 220G7/2a-1 75x50 II 120 265

mbar

4

0


kW

//

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(7)

U2/1 -155x50 IG7/2a-1 65x50 II

U2/1-165x50 IG7/2a-1 75x50 II

(1)L8Z/2, L8T/2 mbarM9/1a- 165x50 M9/1a- 185x5064-240 52-203760-2860 620-2420

\

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85 2201 20 265

85 2201 20 265

85 2201 20 265

(AL8Z/2, L8T/2U2/1- 165x50 G7/2a- 165x5052 - 200 90 - 265620-2380 1070-3155

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Burner types L8Z/2, L8T/2Comb, head U2/1 - 145x40Rating kg/h 6 0 - 2 1 7

kW 715-2585

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KW 500 1000 1500 2000 2500 3000 35C

KW 500 1 000 1 500 2000 2500 3000

mbar

(6Burner types RL8/2Comb, head U2/1 - 1 55x50 G7/2a - 1 65x50Rating kg/h 52 - 230 90 - 277

kW 620 - 2740 1 070 - 3300

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kW 680-2620 955-3075

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Burner types RL8/2Comb, head U2/1 - 1 65x50 G7/2a - 1 75x50Rating kg/h 48 - 205 80 - 266

kW 570-2440 955-3170

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1000 1500 2000 2500 3000 3500 KW 500 1500 2000 2500 3000 3500

26

Sizes 10 and 11

Dimensions mmNo. Combustion head Fig. 1 d No. Combustion head Fig. 1 d

(1+2) M1 0/2-1 85x50 IV 140 265 (3) M1 1/1 -245x70 IV 170 325M1 0/2-200x50 IV 140 265 M1 1/1 -260x70 IV 170 325

mbar

10

4

9

-iKW 5(

(1)Burner types L10T mbarComb, head M1 0/2 - 1 85x50 M1 0/2 - 200x50Rating kg/h 95 - 380 85 - 325

kW 1130-4525 1010-3870

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10

8

4

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Burner types RL11Comb, head M 1 1 /2 - 245x70 M 1 1 /2 - 260x70Rating kg/h 1 30 - 440 1 20 - 385

kW 1550-5240 1430-4585

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00 1500 2000 2500 3000 3500 4000 4500 5000 55C

(2)

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Burner types RL10Comb, head M10/2 - 185x50 M10/2 - 200x50Rating kg/h 90 - 380 80 - 31 5

kW 1 070 - 4525 955 - 3750

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28

(5)

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KW 5

Burner types RL8/2Comb, head M9/1a- 165x50 M9/1a- 185x50Rating kg/h 58-248 52-218

kW 690-2955 620-2595

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SizeS

Dimensions mmNo. Combustion head Fig. I

(1-3) M9/1a-165x50M9/1a-185x50

9090

240240

(1)mbar Bur

ConRat

ler types L9Zib. head M9/1a- 165x50 M9/1a- 185x50ig kg/h 68 - 260 63 - 250

kW 810-3095 750-2980

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mbar Burner types RL9Comb, head M9/1a- 165x50 M9/1a- 185x50Rating kg/h 63-310 60-250

kW 740-3690 715-2980

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Burner types L9TComb, head M9/1a- 165x50 M9/1a- 185x50Rating kg/h 67 - 290 63 - 250

kW 800-3455 750-2980

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1000 1500 2000 2500 3000 3500 4000

11.2 Burner types M/MS and RM/RMS

Combustion of residual oilWith residual oil burners types MS and RMS, the oilthroughput in relation to nominal rating must not beless than 100 kg/h. It is also recommended that slidingtwo stage RMS burners are used when burning thisfuel.

Size 5


(1) M5/2a-1 25x40 IIM5/1a-1 25x40 IIM5/1a-1 45x40* II

506565

160180180

* Special combustion head

(1)mbar Burner types M5Z

Comb, head M5/2a-125x40 M5/1a- 125x40 M5/1a-145x40Rating kg/h 20-70 28 - 106 25-81

kW 225-810 310-1190 280-915

Note burner M5ZSize 5 M burners cannot be used in Germany. The datagiven in the capacity charts are the maximum values. Thefigures actually obtainable depend on the combustionchamber and should be determined by testing on theappropriate heating appliance.

Size?


(1)

(2)

(3)

Мб/1 а-1 55x50 IIМ7/1а-1 55x50 II

Мб/1 а-1 65x50 IIМ7/1 а-1 65x50 I

Мб/1 а-1 7 5 x 5 0 IIМ7/1 а-1 75x50 II

100100

90100

90100

220220

200220

200220

(1)mbar Burner types MS7Z, RMS7

Comb, head Мб/1 а- 155x50 M7/1a- 155x50Rating kg/h 50-159 70-175

kW 560-1785 785-1965

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200 400 600 800 1000 1200 1400 1600 1800 2000

(3)эаг

2 •

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Burner types M S7Z, RM S7Comb, head M6/1 a - 1 75x50 M7/1 a - 1 75x50Rating kg/h 40 - 1 1 1 60 - 1 70

kW 450-1250 675-1905

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2kW 2

Burner types MS7Z, RMS7Comb, head M6/1a- 165x50 M7/1a- 165x50Rating kg/h 45-127 65-175

kW 505-1430 730-1965

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00 400 600 800 1000 1200 1400 1600 1800 20C

200 400 600 800 1000 1200 1400 1600 1800 2000

30

Sizes 8,8/2 and 9

Dimensions mmNo. Combustion head Fig. 1 d No. Combustion head Fig.

(1) M7/1a-1 55x50* II 100 220 (4) G7/2a-1 65x50 IIM8/1a-1 5 5 x 5 0 II 110 240 G7/2a-1 7 5 x 5 0 II

(2) M7/1a-1 6 5 x 5 0 II 100 220 (5 + 7 + 8) M9/1a-1 65x50 IIIM8/1a-1 65x50* II 110 240 M9/1a-1 85x50 II

(3) M7/1a-1 7 5 x 5 0 II 100 220 (6) U2/1 -155x50 IM8/1a-1 75x50 II 110 240 U2/1 -165x50 I

d

120 265120 265

90 24090 240

85 22085 220


mbar

•

6

4

0

2

KW 5C

mbar

10

8

6

4

2

0

-2

KW 5

mbar

12

10

8

6

4

2

0

-2

KW 5

(D

Burnertypes MS8Z, RMS8 mbarComb, head M7/1a- 155x50 M8/1a- 155x50Rating kg/h 70 • 206 75 - 244

kW 785 - 2320 845 - 2740

//

/

^*{\

//

^.---

^**1*~

s

_^-

s\

— vN

\

4,\

\X,

4.x^

X.1

(4

Burnertypes MS8Z/2, RMS8/2Comb, head G7/2a - 1 65x50 G7/2a - 1 75x50Rating kg/h 95 - 280 90 - 274

kW 1070-3155 1010-3075

.^у''

s

0 1000 1500 2000 2500 3000 KW 500 1000 1500 2000

(2)Burnertypes MS8Z, RMS8 mbarComb, head M7/1a- 165x50 M8/1a- 165x50Rat ng kg/h 65 - 1 92 65 - 233

kW 730-2155 730-2620

//

/

/

S

^r

/

N4

_/\

^\\

ч

\\

^

ччч1

ччуч1

\ ч\ч

ЧЧ\\

YS1 1

2500 3000 350(

(5Burnertypes MS8Z/2, RMS8/2Comb, head M9/1a- 165x50 М9/1а- 185x50Rating kg/h 60-254 60-215

kW 675 - 2860 675 - 2420

,/

// .

' /

//

' /"~7_

'

\

чч\

s,ч

ч,ч,ччч

sV

00 1000 1500 2000 2500 3000 KW 500 1000 1500 2000

(3)Burnertypes MS8Z, RMS8 mbarComb, head M7/1 a -175x50 M8/1a- 175x50Rating kg/h 60 - 1 76 65-209

kW 675-1975 730-2345

/

/1

ff

/

f

//

'

\^ч\\ч

\

VX

N

Ч

\

ЧI

чч\

ч1

S.ч4S

Ч12500 3000 350

(6

Burner types MS8Z/2, RMS8/2Comb, head U2/1 - 1 55x50 U2/1 - 1 65x50Rating kg/h 80-233 85-212

kW 900 - 2620 955 - 2380

>/

1

//1

//f I1f

\

ччч

ч\чччч

чччL

ч

00 1000 1500 2000 2500 3000 KW 500 1000 1500 2000

VчI2500 3000 350

31

(7) (8)mbar

6

4

2

0

-2

KW 5C

Burner types MS9Z mbarComb, head M9/1a- 165x50 M9/1a- 185x50Rating kg/h 90 - 275 80 - 265

kW 1010-3095 900-2980

>

/77If

ff

1

l—r~/ ^

f

^\

^sN

s"V

ss\

sN

чч\

s^^4

ччч

s.

0 1000 1500 2000 2500 3000 3500 40C

6

4

0

-20 KW 5C

Burner types RMS9Comb, head M9/1a- 165x50 M9/1a- 185x50Rating kg/h 90 - 328 80 - 265

kW 1010-3690 900-2980

j1

,I

дfl

fjI

rf \

S4,SI

Vv

s\.

\

4.X,

\

ч\

s.\

чч.ч

xчу

Ч.ss

0 1000 1500 2000 2500 3000 3500 400

Sizes 10 and 11


(1) M10/2-185x50 NM10/2-200x50 N

140 265140 265

No. Combustion head Fig. I d

(2) M11/4-245x70 N 170 325M11/1-260x70 N 170 325


(1) (2mbar

16 •

1 4

12 •

10 J

6 -

4

?

0

-9

Burner types RMS1 0 mbarComb, head M1 0/2 - 1 85x50 M1 0/2 - 200x50Rating kg/h 1 00 - 403 90 - 334

kW 1 1 25 - 4525 1 01 0 - 3750

j£_

.

//f

j~j

sS

/

/ff

"\_

ss\ч

ч

ss>v

\V

s\

\s

ч

s\

чs

16 -

12 •

10 -

6 -

4 •

2

0 -

-2

Burner types RMS11Comb, head M1 1/2 -245x70 M1 1/2 -260x70Rating kg/h 140-466 130-408

kW 1575-5240 1460-4585

J

JF

f ,/

.f

f

/f

f

у//

.f \ >

sS

_SJj

s\

чX

vS

> _"*

4v

x.s

v.\

V

^y

ч

ч."V

X\

VS

Ч

"Ч>

x Ч

KW 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 KW 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

32

12. Nozzle selection

12.1 Two and three stage burners

It is recommended that solid or semi-solid nozzles are usedwith a spray angle of 60° or 45°. Due to the variousconfigurations of combustion chambers encountered onindividual heating appliances, no binding information canbe given.

Please note that nozzle spray angles and patterns alterwith the atomising pressure. The data given on the nozzleonly applies with a pressure of 7 bar.

On two stage burners the total burner capacity must bedivided between two nozzles. Usually nozzle 1 is sized tohave sufficient capacity for basic load at approximately 2/3of the total load. At peak demand nozzle 2 is added to thethroughput of nozzle 1. A different nozzle ratio may berequired depending upon the heat demand and the designof the heating appliance (e.g. boilers with high combustionchamber resistance).

Nozzle selection for residual fuelsNozzles that are too small are frequently used for residualfuels and therefore soon become blocked. We recommendthe following nozzles sizes as minimum sizes:

from 2 - 3 USgph up to approx. 76 mm2/s at 50Cfrom 3 USgph up to approx. 450 mm2/s at 50C

On two stage burners neither nozzle should be smallerthan indicated.

The charts are based on distillate oil EL with a viscosity of4 mm'/s at 20°C.

Removing and replacing nozzlesWhen removing the nozzle, the nozzle head must be heldwith a spanner. Before replacing the nozzle ensure that thenozzle insert is a tight fit.

Cleaning the nozzle/ It is not recommended to clean the nozzles. A new nozzle .-'*i should be used.

Nozzle spray characteristic

Hollow spray Semi-solid spray Solid spray

Spray angle

Atomising pressuresOil ELOilM + S

10-16 bar.20-25 bar

NoteOn type Т burners we recommend the higheratomising pressure is set.

Nozzle selection chartsThe charts are based on details supplied by the nozzlemanufacturer. With variations in viscosity andmanufacturers tolerances a deviation in throughput of ±10% may result. It should be noted that on residual oilburners variations in throughput may occur.

These variations are due to differences in fuel density andviscosity range (atomising viscosity up to max. 17 mmVsdepending on burner size). Pressure losses in thepreheater and burner fuel system should be taken intoaccount. The precise oil throughput can only bedetermined by weighing.

33

Oil throughput

-1 /| Л A // /y^Vf >[ > Wyy^f-T0 2 4 6 8 10 12 t 14 16 18 20 22

Distillate oil 7= 0.84 [kg/dm3] [kg/h]

24 26 28 30 H/h ]

[ kg/h ]

0 2 4 6 8 10 12

Residual oil у = 0.93 [kg/dm3] [kg/h]

14 16 18 20 22 24

[ kg/h ]

8 10 12 14 16 18 20 22 24 26

Residual oil у = 0.97 [kg/dm3] [kg/h]I ' I i I i I0 2 4 6 8

[ kg/h ]I ' I ' I—' I ' I '—Г"1—!—"—I—'—I < I

10 12 14 16 18 20 22 24 26 28

Pressure bar ,24--

22

}0 _

ti -

j ~

^ (?

j ' '

'' I' ' 1 I ' ': :::.ju ! . , , i ,_ . . , ' . ,

jffi Bttl!

Ш<- 1» r

I ЧУ*>TOP>

^ПШШШШЩЙ- , - ^ -- -* ? j r . , . . . j . . . . .

x ^ « t » ' i ' ( ' >/ \\\i\\\ t' , ' ' , '~*l'.\\ti У , р | , . ' ' , • '

? Z ' g ! ' ;' ;;• ЙЙЙ '

!

' r r ' ? -jZ - ! . . . . ) , i , i f.-

i i ' -У i

ЧГ" ' O^ ÂSl 3^ O/^^W

( c^5l "W^d vQftC^S^c^^yCi ^"''•Oj/j ^ /^^b jf С) УЪ/^уоУ1

£> U '' П г ^К^Лт ' &Р ^^4^1 "^/"^J ~^^ **J "V "^ "^ ^/' ; , ; ? : ; ! : ; ! : ; ! . ; ! . ; ' : z!i / ^ / ' ' У

. , _ _ „ . . , . ^ . , . . . , ./^,

i' ( ' ' ' i ' i ' î ' i * ^ « ' i ' ' ' ' ' ' ^^

1 ? ? ; ' ^ ; I • ' I ' ?

^ - i - j - -. ? _ L .Г J

7j /i

Ж ?л/К>Ж

o^vCS$ж£^Q^S

^ *

^,

.

&Й.

C^J

<CU iJ OU JU -4U t<J UU J

Distillate oil у = 0.84 [kg/dft Ikg/h] [ kg/h ]"I 'M i ' I I | i I I I | ШЧТЧ'Чищ!

18 20. , . . . . , . . , , . . , . . .ЦП.Ц-ГГ1 I ; 1 Г 1 I |||И|1ИЦ111Ц I |

25 30 Гв 40 45 50 60 70 80 90 100 110

Oil throughput Residual oil y^0.gg^g/drn3][kg/h] [ Kg/h ]| < , . | « l r l T ' > i | > ' ' I | i i i i | i ' > T | . . . . | . . . . |

20 25 :*C 35 40 . 45 5O 60 70 вО 90 100 120

•П 25 30 35 40 45 50 60 70 80

Pressure bar j> KJ

Л-

'•'• Г

_

/

s

f

/v

•*

"\t&A

!_2 2f.t

Jf

L1

::t\ its IY-i-l \

Ф^рЧф ~rtyj

J t ' j f; * a j (

j ! . ' i, ' *i i ^

' i '< ' '' ' '' '

* 4 * • ' *'

Ш j£[f fl. 1

t', 1[ 1 /Г I7 3 """

•$"Ш? 't -j

L.(' \'1

!.,!,!< '

~?t ^ -t

(t

$?

/

/

,/

/,' /

I/

t

'

у

V*

:/

r/

/

^/

у

/г f

t<>

100 120 140 160 180 200 250

Distillate oil -/ = 0.84 [kg*dm3][kg/h]

t t - -

/ /_l }

,

îIKt~Ш^ "to)

o/ °i

Ж. "' ?

'

^f

. '

"T1"" ' I ' '"90 100 120 140

щтгп+ n"1""t,

I1

.Ц_

300 350 400 500 6OO [ |/h ]

[kg/h]••-"•' ' ' ' f г f * | r | , | , , . | , , , , , | , , , , j , , , , | , , , , |

ЯО 1СО «20 140 160 180 200 250 300 350 400 500

12.2 Sliding two stage and modulating burners

The charts shows the throughput of the spill type nozzle inrelation to the supply pressure. The pump pressure on RLburners should be between 20 and 30 bar.It should be ensured that the minimum pressure doesnot fall below 20 bar even at the lowest regulator cam

On RlvlSTjuTnersJhe pump pressure must not fall"beiov/ Un KMbbjjrner§,the pump pressure must not tall belgy£>L_25 bar/When/due to nozzle sizing, the burner rating with

the return flow closed (regulator position 10) can only beachieved at a pressure below 25 bar, the pump pressuremust be increased to 25 bar and the higher oil throughputthat results is reduced by limiting the oil regulatormovement. This is done by adjusting the limit switch in theservomotor to the appropriate lower regulating position.The range of regulation is reduced by this action.

Nozzle return pressure ••, > • ,Spill type Nozzle КЗ / WB3 : : h V Cv, .,1чThe nozzle return pressure must be measured wheni*.*•£:/•'commissioning. In normal cases it sh;ould,not be set below5 bar for partial load. < f f t l ) , ,

Spill type nozzle WS4The nozzle return pressure must be measured whencommissioning. In normal cases it should not be setbelow8 bar for partial load.

Solenoid valve group, sizes 5 to 7

Solenoid valve group, sizes 8 to 11

Atomising pressure

Burner type Atomising pressurebar (approx.)

RL5toRL11RMS7 to RMS11

20-3025-30

Sp;7/ type nozzles

NoteEach' burner is4additionany; subjected to an oil throughput

'ratings'test witMhe spill type nozzle during final testing.fThis ratifies, test-is/u^felly carried oqt with oil EL. Thedifferences^Hich'eJicur on oil §' i.e. on RMS burnens"?(density ana viscosity) are taken into Jiceourtt wftb acorrecting factoE'Tfiese test bed measurements can onlybe used-as guid£|the,s; Exact-measuring has to be carriedout op ske. Site specific Gbndifions, such as oil quality andring-main pressure гтшз!Йэе taken into account.

the nozzjesf! Ц ; I \'is disniferitled intblife jndividual parts and

i. trje filter should always beare faulty or worn, the

. I •; ;\W" i%\. ;'-S.v... *.• 'ifNozzles$election Charts*

:-rjrbe;chprt$ar|i based;on'i e^ai[ssupplied by the nozzlei m^rlufactu'rer VVith variaHpW'jn^yiscosity and• |flar|ufactefrers tblerafipfe!& |JeV|ation in throughput ofK± 10% mi result. It sboutob^noted that on residual oil

:l bbr|i4rsxyanatlopsiin tfefpughpuf may occur.

These varrations aretfue to differences in fuel density andviscosity range, (atomising viscosity up to max. 17 mmVsdepending,on burner size). Pressure losses in thepreheat'er and burner fuel system should be taken intoaccbunt'The precise oil throughput can only bedetermined by weighing:

Return pressure 1/4" test point

35

Nozzle selection chart type WB3/K3Spill type nozzle type WB3 to 70 kg/h

type КЗ 80 to 180 kg/hSpray angle 50°

190

180

170

160

150

140

130

120

110

100

90

80

70

65

60

50

D)

| 40

О)

О ои. о

30

190

180

170

160

150

140

130

120

110

100

90

80

•70

65

60

55

50

s" Nozzle selection chart type W, series 4Spill type nozzletype W, series 4

V Spray angle 50°

CO

«иQ.

2-

NNО

COCO

5Щaг-NNО

460-

440

420

400

380

360

340

320

300

280

260

240

220

200

180

160

140

120

100

80

603аО)

1 «20

W 4 6 0

W420

W390

W360

W330

W300

W275

W250

W225

W200

W 180

W 160

W 140

W125

W110

W 9 0

W80

W 7 0

W 6 0W 5 5W50W 4 5W40

я

0)>

0)N

NNО

и

20 25 30

Supply pressure bar20 25 30

Supply pressure bar

Example of nozzle selection, type WB3Oil throughput required:Nozzle size from chart:Supply pressure from chart:

Example of nozzle selection, type WOil throughput required:Nozzle size from chart:

50 kg/h55

_ 24 bar Supply pressure from chart:_

160 kg/h_W160

24 bar

36

Jl №12(50)декабрь 2004

Главный редактор

Сергей Бирюков

Зам. главного редактора

Сергей Кузнецов

Редакционная коллегия

Павел АсташкевичАлександр ФрунзеВиктор ЙовчикЮлия Герасимова

Дизайн и верстка

Ирина ГалкинаИрина Чикина

Отдел распространения

(095)777-12-15e-mail: [email protected]Марина ТрофимоваЮрий ЦаревСергей Лукин

Отдел рекламы

Юлия Суханова

Адрес редакции:

127015 Москва, ул. Бутырская, д. 41 /47«ИД Скимен»тел./факс: (095) 777-12-15www.dian.rue-mail: [email protected]

Издатель и учредительООО "ИД Скимен"Отпечатано в ОАО ордена Трудового Красного Знамени

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За содержание статьии ее оригинальность несетответственность автор

Содержание

омпоненты

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41

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50

Полное или частичноевоспроизведение материаловдопускается только с разрешения000 "ИД Скимен"

Информацию о подпискесм. на последней странице журнала

CD-ROM с журналами «Схемотехника» (с. 55).

Конкурс радиокружков (с. 20)ч Выставка ЭлектроТехноЭкспо-2004 (с. 30).Новости от «Аргуссофт Компани»(с. 38). Выставка ChipExpo-2004 (с. 43). RainbowTechnologies открывает новый офис в Новосибирске (с. 48). Содержание журнала"Схемотехника" за 2004 г. (с. 53). Подписка-2005 (с. 55).

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