Quick Reference to Installation and Testing

1. Install the burner (with an air cylinder of 114 mm). Connect the oil piping and airpiping.

2. Fill around 1.5 liter waste engine oil into the smaller oil tank until the heater issubmerged.

3. Fill the fuel oil into the bigger oil tank fully. (It should be done like this everydayso as to prevent the oil-pumping system from exhausting the tank. And somepriming oils may be filled at the outlet pipe of the oil pump if the oil-pumpingsystem exhausts the tank unintentionally).

4. Connect to the power conductor (220 V/5 A) at the lower bigger oil tank. The oiltemperature in the bigger oil tank may maintain automatically the constanttemperature at about 40℃.

5. The power plug (220 V/10 A) on the right side of the burner should be connectedto the outlet line of control power supply on the electric control box of either thebaking varnish workshop or the boiler, while we ensure contacts of the controllermay have efficient capacity. If the capacity is inefficient, we should install anadditional relay (220 V/10 A).

6. After the power supply is connected, the oil service pump should be functioning,and it won’t stop working automatically until the oil is transmitted into place. Thefuel oil starts heating when the heating indicator light gets on. The oil temperatureof the waste engine oil is determined at around 95℃. After 6-8 minutes when thetemperature is reached, the burner may function by firing. We should try to findreasons (such as the waste engine oil has high water content, and the compressedair can’t work normally) when we can’t fire the burner for the first and the secondtimes and we will go on firing after these problems are solved.

7. The size of the flame may be adjusted to the proper length by slightly adjustingthe pressure knob in accordance with the actual conditions (the capacity and sizeof the thermal exchanger, and the blast volume), and we will press the button afteradjusting.

8. Observe the combustion situation of the flame through the observation window,and loosen the set screws of the air shutter knob, and adjust the air shutter until ithas efficient combustion and complete emission. And fix the set screws of the airshutter knob.

9. The testing is completed. But remember that don’t blend gasoline, antifreeze andwater into the fuel oil.

10. The unit should have a regular cleaning every other month. Loosen the hangingnuts and pull out the burner to clear the carbon deposits on the air plate and thefire stick. And re-assemble them as they had before cleaning. Look to the relativeposition of the fire stick (as shown in the figure above).

*If you have any questions or any trouble with our burner,please send email to your saler ordirectly:tomzhang_techsupport1@kingweienergy.com

edwardwang_techsupport2@kingweienergy.com

Operation Manual

on

Multi-Fuels Fired Fully-Automatic Burner of Kingwei Brand

● Read carefully the Operation Manual before starting and repairing the burner● Burner and its supporting facilities must be operated by qualified personnel● System power supply must be cut off before operating burner● Accidents and risks may arise due to improper operation

Qingdao Kingwei Energy Saving Equipment Co.,ltd

Contents

I. Main Features

II. Range of Operation

III. Oil Supply System

IV. Main Construction

V. Installation

VI. Maintenance

VII. Troubles and Solutions

I. Main Features

Qingdao Kingwei Energy Saving Equipment Co.,ltd specializes in producing Multi-Fuels FiredFully-Automatic Burner of Kingwei Brand. Having scientific design and using qualitycomponents and having precision installation and testing, the equipment possesses the functions ofenergy conservation and friendly-environment, as well uses multiple fuels especially the wastefuel oils (waste engine oil and waste vegetable oil), and realizes the fully-automatic control overthe combustion process by adopting computerized control with the state patent (the state patent No.200520000333.0) and the unique combustion technology. Widely used in the equipment integratedwith the heat exchanger, such as large and small-sized industrial and utility boilers, coatingmachines and auto baking varnish workshops. Exhaust gas emission reaches the standards and theunit is approved by the environment protection authorities. The unit has the following featuresthanks largely to some measures on its design and construction:

Good fuel atomization, less energy consumption and low noises

The burner uses a special nozzle to burn and inject evenly fuels by using the compressed air as theprimary air. The fuel oil may obtain satisfactory atomization effect when the air pressure is ≥0.05MPa. Therefore the unit has less energy consumption and low noises, because it needs noatomization medium.

Good fuel-air proportioning, stable flame, high combustion efficiency andfriendly-environment

The burner uses cyclone and straight-through flow simultaneously, and may obtain relativelysatisfactory fuel concentration field by enabling the fuel and the combustion air to mix completely,while the cyclone may cause the reflow of the hot flue gas, improving greatly the stability of theflame. Therefore the unit may have an efficient and complete combustion and a thorough emission,and has less pollution to environment, complying with the strictest regulations on air managementin the world.

Safe and reliable with fully-automatic control

The burner uses the world-class flame supervision and combustion safety controllers, realizing thefully-automatic control including the air supply, firing, fuel injection, combustion, stop and re-startaccording to the requirements for operation safety, and it may satisfy the technologicalrequirements of boilers and kilns. And it may stop automatically when there is trouble in anyprocess of the control.

Easy installation

Each burner is equipped with a sliding flange nested on the short blast pipe located at the rear ofthe burner head. It may be operated only after the burner head will be placed in the correctlocation by fixing the flange on the furnace and adjusting the position of the flange on the shortblast pipe, and after the power supply, the compressed air pipe and the oil-feeding pipe areconnected.

Convenient maintenance

Routine maintenance is taken into account in the design of the product. It is very convenient forthe key elements to dismantle, clean and change. And the unit adopts peculiar physicalphenomenon, and there are no wear parts and consumables during the routine operation, whichmay lower costs considerably.

Fig 1

1. Oil Storage Tank2. Drift-Flux Oil Absorption3. Oil Supply System4. Oil Supply Pipe5. Oil-Level Control6. Oil-Level Control7. Heating Pipe8. Thermostat9. Smaller Oil Tank10. Fuel Pre-heater11. Fan

12. Joint for Compressed Air13. Air Pressure Gauge14. Pressure-Regulating Valve15. Solenoid Valve16. Oil-Water Separator17. Nozzle System for Combustion Unit18. Flame Ring19. Fuel Nozzle20. Suction Pipe

Air and Fuel Oil Flow Chart

Temperature Set-upVegetable Oil 140℃Waste Oil 100℃Diesel Oil 0℃

II. Range of Operation

As the heating object and its service situations of the burner differ, the pressure of the furnacehearth varies. When the backpressure (pressure of the furnace hearth) of the burner increases, theoutlet airflow of the fan decreases, and then the injection pressure must be lowered or the injectionvolume must be decreased by changing a smaller nozzle so that the flow of the fuel oil can bematched with the airflow. The higher the backpressure is, the smaller the airflow of the fan is, thesmaller the combustion capacity of the burner. Therefore the burner may function within certainrange, when the backpressure is lifted to certain values, the airflow drops sharply, and firing andcombustion situations deteriorate greatly even the burner gets quenched, no matter how wedecrease the injection volume, we can’t ensure the burner may have a normal combustion.

III. Oil Supply System

They maintain good sealing when the filter, the coupling block and the oil-resistant hose areinstalled at the outlet end of the fuel oil pump. The filter can’t be damaged, and change it if it isdamaged otherwise some foreign substances will enter the oil pump and block the precision oilpump. The outlet hose is connected to the one-way valve, and the fuel oil is transmitted intohigh-temperature fuel oil supply station through the copper tubing. The oil level ofhigh-temperature fuel oil supply consists of a level control float ball and a computer-controlledswitch. The oil level may be adjusted by adjusting the computer program.

IV. Main Construction

Photo ResistancePhoto resistance is a device that supervises the flame. Photo resistance may enable the controllerto stop working within 10 seconds and whilst on the controller fault indicator light (red) gets on,because photo resistance can’t sense the luminosity of the flame if the flame can’t be fired orflame is quenched during the operation when the burner initiates. On the contrary, under thecircumstances that there is a strong ambient light illumination, photo resistance may sense theambient lighting, and thinks the flame is burning, enabling the controller to have improperoperation, that is, the controller will not inject oil when starting while it will not stop injectingwhen operating. Therefore we should dispel the interference of ambient lighting to the photoresistance.

Fault Indicator Light (Red)The controller will stop working within 10 seconds and the fault indicator light (red) gets on whenthe burner can’t start or operate normally due to some reasons. Facing this we should try to findthe reasons possible to cause the troubles, and dispel the trouble, and then press the button of thefault indicator light (red), the burner will function again.According to the requirements users may install a fault warning device that will give a faultalarming when the burner is in trouble. Once the red light gets on, the button of the fault indicatorlight (red) can be pressed after around 1 minute. And the burner should be started again with themanual reset.

Computer Program ControllerA computer program controller is a device controlling the normal and safe operation of the burner.A series of program operating time has been preset to ensure the reliable and safe operation of theburner for the sake of safety except that burner is started and operated with the prescribedprogram.

Fig 2

21. Computerized Automatic Controller22. Thermostat23. Electric Heater24. Heating Relay25. Heating Device26. Photoelectric Control27. Oil-Level Relay28. Oil Temperature Control29. Oil-Feeding Relay30. Oil-Feeding Device31. Fan-Blower32. High-Pressure Transformer Igniter33. Photo Cell

V. Installation

Burner and FlangeFix the flange and seal ring of the burner on the support.

Oil PipeInstallation of oil pipe, oil storage tank, oil float and oil pump. If you store oil with an auxiliary oiltank outdoors, please mount the antifreeze equipment around both the pipe wall and container toprevent the water in the waste oil from freezing or prevent the waste oil from thickening

Connection of Power SupplyPut the plug on the burner into the socket on the boiler, and connect the power line of thethermostat on the bigger oil tank to the power supply.

Connection of Compressed Air SupplyConnect the air pump to the coupler of the air piping. We have installed an oil-water separatorbetween the compressor and the air piping to avoid the shutoff trouble caused by the water in theair piping.

Special Parts1. Oil Tank2. Oils in the oil pre-heater/heating oil-storage tank. The power line in the plastic box mounted

at the bottom of the oil tank should be connected to the power supply directly.3. Oil-pumping device should be mounted on the oil storage tank or the auxiliary oil storage

container connecting to the oil piping, which transmits automatically the fuel oil with apreheating temperature of 40℃ into the smaller oil tank.

4. A floating sucker should be connected to the bottom of the oil piping and inserted into the oilstorage tank or the auxiliary oil storage container.

Preparations before StartingIf the unit is used for the first time, fill manually into the smaller tank of the burner to the half ofits charge.

WarningWhen the oil level is too high, the float switch will turn off automatically; while the oil level is toolow, the heating pipe will be damaged.The burner will function automatically when the fuel oil is heated to the prescribed temperature.

RulesEstablish the oil consumption by adjusting the primary air regulator.Establish the emission of the exhaust gases by adjusting the second air regulator.

VI. Maintenance

Discharge the water deposit and sludge from the water drainer on the smaller oil tank of the burnerwhen the equipment is re-operated after a three-day shutoff.

Monthly Work

Clean the fuel oil filter of the oil storage tank and the strainer mounted before the floating sucker.Discharge the water deposited in the oil storage tank.Clean the photo cell.Clean the igniter electrode and the flame ring. Spray the nozzle with the compressed air and checkthe igniter electrode distance (see attached Fig 3).

Fig 3

Annual Maintenance before and after the Operation

Do the same as the monthly maintenance described above, and place emphasis on the generalcleaning of the heating pipe and the smaller oil tank on the burner.

VII. Troubles and Solutions

Troubles Reasons Possible Solutions

Burner can’t be started 1. There is no voltage or lowvoltage on the power line.

2. The heater of the smaller oil tankhas an open circuit.

3. The power fuse is broken off.4. There is no compressed air or the

pressure is over-low.5. There is something wrong with

the solenoid valve.6. The oil temperature is so low that

the fuel oil is too thick to beinjected into the smaller oil tank.

1. Check the reasons anddispel the trouble.

2. Check the heating circuit.3. Change it.4. Connect to the

compressed air supply andadjust the pressure.

5. Check the solenoid valveand change it if necessary.

6. Have heat preservation onthe oil piping.

Burner injects oil butoften stops (red light ison) because it can’t fire.If the fuel oil has agood state (which is notcontaminated by waterand the like) and it hasa good atomization, thetrouble will lie in thefiring device.

1. Firing circuit is damaged.2. The conductor of the transformer

igniter is ageing and loses itsfunction.

3. The conductor of the transformerigniter is not stranded well.

4. The transformer igniter isdamaged.

5. The distance between the igniterelectrode ends is incorrect.

6. The electrode dischargeselectricity toward the ground(housing) because the electrodeis dirty or the insulation isdamaged. Whilst check theinsulated porcelain.

1. Check the whole circuitand repair it.

2. Change it.3. Strand it tightly.4. Change it.5. Adjust it to the correct

position as shown in thefigure.

6. Clean and change them ifnecessary.

Burner injects oil butoften stops (red light ison) because it can’t fire.

1. There is some water in the fueloil.

2. The combustion airflow is toostrong.

3. The vent between swirler andburner head is too wide.

4. Fuel nozzle is worn or dirty.5. The blast motor or the starting

capacitance is damaged.

1. Clean the bigger oil tank,and drain the water at thetank bottom.

2. Decrease the combustionairflow.

3. Adjust the burner head tothe correct position.

4. Clean or change it.5. Repair or change it.

Burner injects oil butoften stops after theflame has burned for afew seconds (red lightis on). There may besomething wrong withthe flame controller.

1. Photo cell is damaged or blockedby the oil smoke or it is notplugged well.

2. The ventilation is inefficient.3. The loop of the photo resistance

is damaged.4. The swirler and the burner head

are dirty.

1. Change or clean it andplug it well.

2. Check the boiler and ventof the smoke pipe, andclean them.

3. Change it.4. Clean them.

Burner starts very late. 1. The heating pipe and thethermostat in the smaller oil tankof the burner are very dirty orthere are troubles on them.

1. Clean the heating pipe andthe thermostat, and changethem if necessary.

Oil pump can’t pumpthe oil.

1. The oil pump is very dirty.2. The strainer mounted before the

floating sucker is very dirty.3. There is something wrong with

the oil-pumping motor or thestarting capacitance.

4. The fuel oil filter is blocked.

1. Clean the oil pump.2. Clean the strainer.3. Repair or change them.4. Change it.

There are too manycarbon deposits on thefuel nozzle and theflame ring.

1. The installation position of theflame ring is incorrect.

2. The compressed air is too muchor less.

3. The ventilation in the heatingchamber is inefficient.

1. Adjust the position of theflame ring.

2. Adjust the primaryairflow.

3. Provide efficientventilation.

The flame is not goodwith some sparks.

1. The atomization pressure of thecompressed air is too low.

2. There is too much combustionair.

3. The fuel nozzle is dirty or losesits function.

4. There is some water in the fueloil.

1. Increase the primarycompressed airflow.

2. Decrease the combustionairflow.

3. Clean or change it.4. Pump the water from the

oil tank with a properpump.

The flame has its badpattern with smoke andsoot.

1. The combustion airflow isinefficient.

2. The fuel nozzle is dirty or losesits function.

3. The design of the combustionchamber is not reasonable or thechamber is too small.

4. The injection volume of thenozzle is inefficient, comparedwith the size of the combustionchamber.

5. Flameproof asbestos seal ring isunfit or it is too big.

6. The boiler or the smoke pipe isblocked.

7. The atomization pressure of thecompressed air is too low.

1. Increase combustionairflow.

2. Clean or change it.3. Decrease the injection

volume to satisfy thecombustion chamber, orchange the burner.

4. Change the nozzle toincrease the injectionvolume.

5. Change the size of theseal ring up to thestandards.

6. Clear the carbondeposits.

7. Increase the primarycompressed airflow.

The flame has a badquality with pulsationcombustion or blow-offcombustion.

1. The ventilation has a strong draft(only when there is an IDF to thesmoke pipe).

2. Fuel nozzle loses its function(worn or blocked).

3. There is some water in the fueloil.

4. There is greasy dirt on theswirler.

5. The combustion airflow is toostrong.

6. The vent between swirler andburner head is too wide.

1. Adjust the IDF speed bychanging the diameter ofthe pulley.

2. Clean or change it.3. Pump the water from the

oil tank with a properpump.

4. Clean it.5. Decrease the combustion

airflow.6. Adjust the position of the

burner head, and decreasethe area of the vent.

There is soot at theoutlet of the smokepipe.

1. The temperature of the smokeexhaust is very low, and the smokepipe has bad heat insulation, or thecold airflow enters the smoke pipe.

1. Improve the heat insulation,and seal all the gaps throughwhich the cold airflow mayenter.