p. 1

operation manual for the authorized specialist dual-fuel burner ek 6 gl-ef2 02/2007 14 000 166_rev a

[close]

p. 2

overview inhalt contents overview technical data contents 2 important information warranty product description 3 gas/light oil forced draught burner ek 6.240 6.300 gl-ef2 4 dimensioned drawings 5 gas control system gas pressure drop-diagram 7 start-up mode oil operating mode general safety functions 8 gas starting function gas operating function 9 fuel-air compound control gas valves and instruments group 10 hydraulic valves and instruments group 11 burner head settings 12 mounting to boiler electrical connection presetting 13 gas connection 14 oil connection oil pressure control feed 15 return nozzle rod type rdn burner type ek 6 16 nozzle selection type w1 50° 17 nozzle selection sonic 18 linear drive la 12 19 terminal assignment of linear drive la 12 20 checking procedure 21 gas pressure gas/air flow rate adjusting procedure 22 gas ignition/pilot burner 23 elektronic burner control with electronic compound controller 24 flame detecting system type flw 05 25 servomotor type sad 15.0 26 electrical actuator stm 40 27 starting the bcs etamatic vms/fms electronic compound controller 28 oil pressure switch air pressure switch 29 gas pressure switch 30 flame monitor 31 description 35 basic construction 36 gas pressure regulator 37 double solenoid valve type dmv-d 39 gas filter safety vent valve 40 combination controls cg 15 -30 41 fan impeller 43 burner maintenance 44 exhaust gas test 45 trouble shooting instructions 46 operating trouble 48 system diagram 49 operation functioning operation start-up installation start-up technical data adjusting instructions starting adjusting instructions adjusting instructions overview gas valves and instruments group adjustment servicing instructions 2

[close]

p. 3

overview important information warranty product description important information the burners of type ek 6 gl-ef2 have been designed for the combustion of natural gas or heavy fuel oil the burners should be installed and taken into operation carefully by qualified personnel the work should be done in accordance with the applicable regulations and guidelines only a duly authorized specialist should be entrusted with the installation of the gas system any repair work on monitors limiters and automatic furnace controllers and on the other safety facilities are allowed to be done on the single items only by the manufacturers themselves or specialists authorized by them original parts should only be exchanged by a duly qualified specialist standards and regulations the following standards should be observed in the interest of a safe easyon-the-environment and energy-saving operation of the burner en 676 din 4788 en267 din4787 vde 0116 gas burners with blowers oil atomizing gas burners electrical equipment of furnaces place of installation the burner must not be operated in rooms containing corrosive vapours e.g spray perchloroethylene hydrocarbon tetrachloride solvent etc and tending to heavy dust formation and only up to 60 relativ air humidity adequate ventilation must be provided at the place of installation of the furnace system to ensure a reliable supply with combustion air maintenance the furnace system should be serviced at least once a year by an authorized specialist it is recommended to conclude a maintenance agreement to this effect warranty manufacturer will not accept any warranty if the operating instructions have not been duly observed in the start-up and maintenance of the burner and damages have been caused by improper installation incorrect adjustment unauthorized interference or operating errors product description the burners of type ek 6 gl-ef2 have been designed as dual-fuel burners for the combustion of industrial fuel gases according to dvgw-g206/1 gas families 2 or heavy fuel oil according to din 51603-1 they are fitted with a free-flame burner head as a system to ensure low-nox combustion the burners are equipped with combustion air fan and air pressure switch with test key air box with integral sound absorber actuator for the air dampers oil pressure atomizer with highpressure oil pump nozzle rod return nozzle and oil hydraulic system with pressure switches valves and control shaft pressure hoses and gas combustion system with gas lance head and gas control damper with actuator gas ignition burner electrical ignition system for the oil operating mode the burners are designed for operation with electronic compound control according to din 4755 and din 4756 the user must be instructed in the operation of the furnace system for the installation of a gas furnace system care should be taken to observe din 4756 trgi technical regulation on gas installations the worksheets of dvgw german association of the gas and water sector and the local furnace construction regulations applicable in the country for the installation of an oil furnace system care should be taken to observe din 4755 trbf technical regulation on combustible liquids and the local furnace construction regulations applicable in the country screwed unions of metal used in gas lines should be fitted with approved sealing elements prior to taking the burner into operation make sure to vent the gas line but this should in no case be done through the furnace chamber note in the gas fuel mode a nozzle leverage moves the oil nozzle into a protective position in order to prevent the oil in the nozzle and nozzle leverage from getting coked if the burner is operated in gas mode for a longer period make sure to empty the nozzle rod before start-up 3

[close]

p. 4

technical data gas/light oil forced draught burner ek 6.240 300 gl-ef2 low nox with free-flame combustion technology electronic fuel-air-control stand 05.07.06 com bus tion p ower output boiler furnace p res sure fuels ek 6.240 gl-ef2 ek 6.300 gl-ef2 natural gas 340 2.184 kw natural gas 408 2.500 kw fuel oil e l 655 2.419 kw fuel oil el 816 2.833 kw ac cording line of operation field deviating values on request natural gas e ll ac c en 437 fuel oil e l ac c din 51603 or equivalent viscos ity m ax 6 mm ²/s alternative fuels on request 1:6 for natural gas e 1:6 for natural gas e 1:5 for natural gas ll 1:5 for natural gas ll 1:3,5 for fuel oil el 1:3,5 for fuel oil el deviating values on request continuous ly m odulating bcs 300 on burner or e tam atic alternative elec tronic burner controls in s eparate cabinet 400 /690 v 50 hz 3000 u/m in ip55 isolation clas s f 4 kw 4 kw dn80 pn16 natural gas e p m in 100 m bar natural gas ll p m in 150 m bar at ball valve oil hos es dn 20 length 1500 m m high pressure pump 30 bar m ounted on burner approx 520 l/h 0,75 kw approx 735 l/h 1,1 kw ip40 em ission class 3 according to e n 676 and e n 267 gas operation 70-150 m g/kw h 0 o2 acc en676 oil operation 120-200 m g/kw h 0 o2 acc en267 detailed values on reques t 2,7 m 0,85 0,95 m 2,7 m 0,90 1,00 m m ax control ratio attention lower operation point m ust also be inside the operation field return line pressure max 2 bar operation type electronic air-fuel-compound-control autom atic firing devic e fan m otor gas connection oil connection oil pum p protec tion class nox-em issions dependent on furnace load m edium tem perature fuel flam e length m ax at 3 o 2 guarantee only inside the full load range flame diam eter depends on nox requirem ents acoustic em is sion s ound pressure installation site tem perature of operating m aterial including im pact from heat radiation and heat generation by electrical power loss of built-on c omponents burner weight ce -conform ity 88 db a average value on enveloping surface at 1 m distance clos ed room s or weatherproff on site non-aggressive atm osphere 0°c 40°c with bcs on burner -10°c 40°c with alternative electronic burner c ontrols in cabinet approx 250 kg no ce -confirmity equipm ent for heat generator s ingle audit necessary see m anufacturer declaration hom ologation according european direc tives planned for 2006 operation fields ek 6.240/300 gl-ef2 according to en676/en 267 air temp 20°c altitude 171 m output reduction by approximately 1 per 100 m 20 boiler furnace pressure [mbar 15 full load range ek 6.240 full load range ek 6.300 10 5 0 0 500 1000 ek 6.240 gl-ef2 gas ek 6.300 gl-ef2 gas 1500 2000 2500 3000 combustion power output [mw ek 6.240 gl-ef2 oil ek 6.300 gl-ef2 oil 4

[close]

p. 5

overview dimensioned drawings ek 6 gl-ef2 operating mode the burner is designed as an automatic continuously controllable dual-fuel blast burner for the alternative operation with natural gas or light oil el it is tested according to en 267 and en 676 and fitted with a free flame burner head a system for low nox combustion of fuel application the burners are applicable for the operation at heating boilers steam boilers and air heater with 3-pass draft or reverse furnace design the burner is supplied with connection leads fixed to a terminal block ready for connection to the boiler system the automatic furnace controller is housed in a separate switch cabinet a separate pump unit is built-on the burner bcs design the burner is equipped with an electronic burner control system automatic furnace controller electronic compound controller gas valve leak detector etamatic design electronic burner control automatic furnace controller electronic compound controller gas valve leak detector is placed in the switch cabinet combustion air an overpressure fan impeller with a steep characteristic is provided to ensure a high pressure build-up this ensures a pulsation-free and steady combustion behaviour also on boilers with a high exhaust gas resistance control the fuel-air ratio is controlled by an electronic compound controller with actuators provided for positioning the following control elements air damper oil flow rate controller gas damper sensors monitoring of the main flame by a flame sensor and an approved automatic furnace controller monitoring of the ignition burner by ionisation sensor differential pressure switch is fitted for fan air monitoring a speed control system is used ignition oil mode direct electric high-voltage ignition 2 x 7000 v 80 duty factor direct ignition at reduced start-up capacity max 1,5 times of minimum capacity 1:3 gas mode direct electric high-voltage ignition 1 x 11000 v 33 duty factor by built-in ignition burner heat capacity of the ignition flame 10 of the main flame internal exhaust gas return as a primary precaution to minimize the generation of nitric oxides the free flame burner head will internally suck in combustion gases from the furnace chamber and feed them to the air-fuel mixture the otherwise required equipment for the external flue gas recirculation is not needed any more ek 6.240/300 gl-ef2 ignition gas connection tube 12x1 dimensions in boiler connection plate 5

[close]

p. 6

burner installation hydraulic diagram boiler lining d see dimensioned drawings d1 see dimensioned drawings df combustion chamber diameter t1 150 200 t 250 standard depth of boiler lining option extensions of 100 and 200 mm boiler lining the burner lining must be installed rightangled to the burner tube 1 possible trimming work bevelling rounding as required for reverse boilers for example should done at a diameter not below 70 of the combustion chamber diameter 2 note at reverse furnaces measurement t1 is only a reference value the burner head must jut out by 30-50 mm over the redirection gap for the exhaust gases dependent on the boiler construction the space between the flame pipe of the burner and the boiler lining should be lined with heat resistant material such as cerafelt this space is not allowed to be lined with brickwork hydraulic diagram -din en 143 pi vl 175 176 312 178 178 180 120 143 175 176 178 180 181 184 187a 311 312 349 187 a 181 349 120 air damper pressure gauge option filter pump feed solenoid valve nozzle rod return solenoid valve output control valve pressure regulating valve integrated in pump return oil pressure switch feed oil pressure switch actuator m 181 184 311 349 m pi 143 rl hydraulic diagram -trd 604/72 h in case of trd 604/72 hr control items pos 311 312 need to be tested according to special construction design or must be installed twice 143 pi vl 175 176 312 178 178 180 187 a 181 120 349 m 184 311 m 349 pi 143 181 rl 6

[close]

p. 7

gas control system gas pressure drop-diagram gas control system din trd 155 low pressure 141 147 313 154 153 143 nur bei trd 313a 150 100 141 142 gas 144 dp 314 349 120 air luft 349 high pressure 143 burner air damper ball valve gas filter pressure gauge with stop valve gas pressure regulator safety stop valve test burner with stop valve optional 148 safety vent valve 150 gas damper 153 main gas solenoid valve 154 safety solenoid valve 155 combined ignition gas unit or single components 313 minimum gas pressure switch 313a maximum gas pressure switch 314 leak test 349 actuator in the trd system a compensator must be used from dn 50 nominal bore in the trd 604 72h the pressure switches items 313 313a have been tested according to the special type requirements 100 120 141 142 143 144 145 147 147 141 142 145 144 148 gas l 10 x Ød items 153 154 can also be provided as double valves up to dn 125 gas pressure drop burner ek 6.240 300gl ef2 gl ef2 gl-eu natural gas-druckverlustthe gas mixing unit ek 6.240 300 erdgas pressure drop of brenner ek 6.240/300 gl-ef2 erdgas gas 70 druckverlust [mbar pressure drop [mbar 60 50 40 30 20 10 0 0 50 100 150 200 m ³/h 250 300 e k 6 .2 4 0 e k 6 .3 0 0 pressure drop [mbar qf burner output [kw natural bsvo lu m rate t [bm³/h dgas betriebsvolumenstrom erbetrie gas flow ensrom [bm³/h pressure drop butterfly valve dkg/bvg fully open dn 80 100 Ø 40 Ø 50 Ø 65 Ø 80 druckverlust bei voll geöffneter gasklappe dn 80 typ dkg bvg pressure drop [mbar druckverlust mbar 10 1 10 100 1000 10000 natural gas flowvolumenstrom v [m³/h erdgas 15°c 1013 mbar dv 0,62 rate v [m³/h natural gas 15°c 1013 mbar dv 0,62 7

[close]

p. 8

operation start-up mode oil operating mode general safety functions start-up mode as soon as the furnace system is required to supply heat the electronic burner operation manager receives an operate signal after the selected automatic furnace control program has run down the burner will start the air damper is closed when the burner is out of operation the automatic furnace controller controls and monitors the starting function the burner blower starts to run and the electric actuator opens the closed air damper to its full-load position so that the furnace compartment and exhaust ports are ventilated at the required air flow rate shortly after the pre-ventilation process has been started the lackof-air cut-out must change over to operating position within a certain time i.e the minimum air pressure setting must be reached and maintained until the burner is turned off at the end of the specified pre-ventilation time the air damper will be moved into its partialload position this operation will be followed by the pre-ignition procedure and the oil feed start oil control steepless full load the solenoid valves will open and thus allow the pressurized oil to flow to the nozzle and to the return line the oil will be atomized mixed with the combustion air and ignited a safety period is provided to allow the flame to develop a proper and steady pattern on the termination of the safety period a flame signal must have been received by the automatic furnace controller via the flame monitor and remain on until the regular shut-off the start-up program of the burner has now been completed oil operating mode after the flame has developed the load regulator will be enabled which brings the burner into its operating position the load regulator will now control the burner automatically between its partialload and full-load stages depending on the heat rate required the servomotor will via the controller be given an open or close signal and thus increase or decrease the oil and air flow rates this compound control concept will vary the position of the oil control valve and air damper and thus adjust the oil flow rate in relation to the air flow rate the stepless control will allow the burner to be operated at any desired stage between its partial-load and full-load positions the burner will be turned off from its partial-load position the air damper will be closed when the burner is out of operation and will thus prevent cold air flowing through the burner chamber heat exchanger and chimney the interior cooling losses will be greatly minimized .attention:if there are shut-off dampers in the flue gas tract they must be complete open otherwise there will be a high danger of low-speed detonation or explosion the open-position of the shut-oft damper can be assured by the integration of the ope-ning contact of the shut-off damper in the safety chain of the heat generator gas control steepless full load vollast vollast betriebsstellung tellung operating position load regulator release operating position load regulator release betriebsstellung leistungsregulierung freigabe startlast teillast gasventile zündung leistungsregulierung regulierung freigabe teillast e zündung/ventile pumpe ignition/valves pump partial load start load partial load ignition gas valves ein ein on off aus aus on ein off aus rence of a trouble when using the burner control system type bcs all operational and fault messages may be indicated in plain text on an optionally available operating and display module general safety functions in case a flame does not develop when starting the burner fuel release the burner controller will shut off at the end of the safety period shut-off on trouble a shut-off on trouble will also occur in the case of flame failure during operation air flow failure during the preventilation phase and pressure failure during the whole period of burner operation any failure of the flame signal at the end of the safety period and a flame signal during the pre-ventilation phase external light control will result in a shut-off on trouble with the automatic 8 furnace controller being locked the trouble is indicated by the trouble signal lamp lighting up the automatic furnace controller can be unlocked immediately after a shut-off on trouble by pressing the unlocking key the program unit will return to its starting position and proceed with the restart of the burner a voltage failure will result in a regular shut-off of the burner after voltage recovery the burner can be automatically restarted unless another interlock is active e.g one caused by the safety circuit in any case the fuel oil supply will be immediately stopped upon occur-

[close]

p. 9

functioning gas starting function gas operating function gas starting function as soon as the furnace system is required to supply heat the electronic burner operation manager receives an operate signal after the selected automatic furnace control program has run down the burner will start prior to any burner start and after burner stop the gas valve will be automatically tested for proper tightness the air damper will be closed at burner stop the electric actuator will move the closed air damper into its full-load position so that the burner ventilates the furnace and the exhaust ducts with the specified air flow rate shortly after pre-ventilation start the air failure cut-out must change over to working position i.e the preset minimum air pressure must be reached and maintained until the burner is turned off after the expiry of the preset pre-ventilation time the air damper and the gas control damper are set to their partial-load positions the ignition transformer is put into operation after the pre-ignition time the ignition gas solenoid valves are opened and gas will flow into the ignition burner the ignition gas is ignited by the ignition electrodes attached to the ignition burner the ignition flame is monitored by an ionisation electrode incorporated in the ignition burner i.e the ionisation current is monitored the safety shut-off valves of the main gas burner will only be opened with a steady ignition flame the gas is admitted to the gas nozzles through the gas control damper the combustion air is supplied by the fan the two fluids are intensively mixed in the mixing apparatus and ignited by the ignition flame within a given safety period minimum furnace heat output the combined gas ignition/pilot burner will not be turned off it will continue to burn in gas operating mode for flame stabilisation gas operating function after the flame has been duly developed the output controller will be enabled this brings the burner to its operating position the controller will now automatically control the burner between its partial-load and full-load positions depending on the heat demand the output controller will actuate the electronic compound controller which in turn will control the actuators of the gas control damper and air control dampers and increase or decrease the flow rates according to a specific program the stepless control makes it possible to operate the burner at any desired stage between its partial-load and full-load positions for turning off the burner this must always be in its partial-load position the air damper will be closed when the burner is in its off position so as to prevent cold air from flowing through the furnace chamber heat exchanger and chimney the interior cooling losses will be greatly minimised .attention if there are shut-off dampers in the flue gas tract they must be complete open otherwise there will be a high danger of low-speed detonation or explosion the open-position of the shut-oft damper can be assured by the integration of the opening contact of the shut-off damper in the safety chain of the heat generator 9

[close]

p. 10

operation fuel-air compound control gas valves and instruments group fuel-air compound control this compound pneumatic control system with precision-adjustment capability has been designed to allow the fuel and air flow rates to be steadily varied in sliding mode for an adjustment of the fuel-air ratio over the whole control range in the stepless control mode the load will be controlled at any point within the control range depending on the heat demand the air damper and oil control valve in the return line are provided with one actuator each these actuators serve the positioning of the damper and valve respectively for burner start-up these elements are assigned specific positions for fuel and air in dependence of the burner output in burner operation these positions are approached very accurately this precision is the fundamental condition for a permanent lowemission burning characteristic equipment option speed controller optionally the burners can be equipped with a speed controller in particular when operating the burner over an extended period in the partial-load range electric energy may be saved by reducing the fan speed which simultaneously reduces the noise emitted by the burner fan in this case the fan speed is measured by a namur sensor and controlled in dependence of the set-point value programmed for the respective output power equipment option o2 controller co controller to improve the system efficiency the burner operation manager may be equipped with a residual oxygen/co controller an o2 measuring probe with zirconium oxide sensor measures the residual oxygen in the exhaust gas leaving the furnace and sends the result for correction purposes to the burner operation manager the o2 control option permits fluctuations in the environmental conditions e.g of the combustion air temperature and humidity or calorific value to be eliminated and the excess air volume required for compensation can be considerably reduced set-point deviations are eliminated by adjusting the fan speed or air damper position a co controller only possible with gasfuelled burners can be used to additionally measure the co contained in the exhaust gas by correcting the fan speed and/or air damper position the excess air can be reduced to the co edge the corrective quantities are determined in a system-specific learning process and temporarily stored in the burner operation manager this approach permits the system burner efficiency to be maximized across the entire power range and the combustion process to be optimized for further information see the manufacturer s documentation for the electronic burner operation manager gas valves and instruments group the gas valves and instruments group used with the furnace will be selected according to the specific requirements to be met by a burner system the following factors must be taken into account · burner output · furnace back pressure · gas pressure loss of the burner head · gas pressure losses of the gas valves and instruments group the total gas pressure loss must always be smaller than the available gas flow pressure electronic compound control elektronischer verbund 1a m 2 3 gas oil vl Ölfeed 1b m oil return Ölrl note use should only be made of gas valves and instruments that have been approved in accordance with the burner test specifications 1c air luft m 4 m 1a 1b 1c 2 3 4 gas damper with actuator oil control valve with actuator air dampers with actuators burner boiler combustion air fan 10

[close]

p. 11

operation hydraulic valves and instruments group complete hydraulic valves and instruments group the volume flow control valve installed in the return pipe consists of a bush pressed into the hydraulic valves and instruments group and locked against torsion and a control shaft as the control shaft is turned the contoured configuration of the bush and shaft will change the open cross section for the oil flowing back and thus vary the oil return flow rate control shafts with different control contour parameters are available for adjustment to various oil nozzle sizes this concept ensures that an excellent control characteristic and a wide control range can be covered for a great variety of applications the control contour parameter is affixed to the control shaft by means of an electric marker the current position of the control shaft is indicated by the position display from the min mark low load of burner the control shaft will turn clockwise to the max mark full load of burner if the control shaft has been removed during maintenance work care should be taken when reinstalling it to ensure the right mounting position of the control contour by observing the centre punch mark on the shaft end face in the low load position min the centre punch mark will in any case point up 12 o clock position see figure if the hydraulic valves and instruments group is used in conjunction with nozzle rods not approved as safety shut-off valve according to en 264 an extension module 3 is available which incorporates an additional solenoid valve each in the supply and return pipes the extension module is attached directly to the basic module the modules are sealed against each other by o-rings metal hoses are used for connection between the hydraulic valves and instruments group and the nozzle rod the hose lines must be protected against exterior mechanical damage the hoses must be positioned and mounted in accordance with the applicable technical standards for the installation care must be taken not to introduce torsional or buckling stresses neither by the mounting procedure nor by movements at a later stage specified bending radii of the hoses must not be changed pumpadapter 4 1 3 2 the hydraulic valves and instruments group is an integrated concept that combines several functions of the hydraulic systems of burners its modular construction makes it possible to meet a wide range of requirements and conditions of installation the pump adapter module 1 allows the hydraulic valves and instruments group to be mounted directly to oil burner pumps of any size it is fastened to the pump by means of hollow bolts which are provided with ¼ screw plugs 4 for venting the pump when taken into operation the basic group module 2 is mounted to the pump adapter with the two modules being sealed against each other by o-rings in the supply and return pipes depending on the level of equipment of the hydraulic system oil pressure switches and pressure gauges may be installed in the supply and return pipes of the basic module the solenoid valve in the supply pipe is of servo-assisted type while the return valve is directly controlled the solenoids of the two valves are electrically connected in series which will prevent one of the valves being opened alone if any of the solenoids is defective for the replacement of the solenoid valves during maintenance work it should be ensured that the right valve type is installed in the correct direction of mounting for mounting the solenoid valve in the supply pipe type 321 f 2523 it must be ensured that the direction of flow shown be a stamped arrow on the valve flange is the same as the direction of flow of the oil from the pump to the nozzle rod the solenoid valve in the return pipe type 121 f2523 is marked with a stamped arrow opposite to the direction of the oil flow from the nozzle rod back to the pump basic module extension module control shaft installation 11

[close]

p. 12

start-up burner head settings ek 6 gl-ef2 ek 6.240 gl-ef2 boiler lining ek 6.300 gl-ef2 boiler lining 12

[close]

p. 13

installation mounting to boiler electrical connection presetting ignition burner zb 12 burner mounting for mounting the burner to the boiler make sure the connection plate has been prepared according to the dimensions given in the technical datasheets · install the stud bolts in the connection plate · put the insulating backing and burner in place and fasten by bolts check before burner installation 1 select the nozzle according to boiler output and combustion chamber geometry 2 set the mixing and ignition unit according to the boiler output for the standard factory setting refer to the burner head settings 3 set the ignition electrodes on the nozzle 4 check the burner tube installation depth according to the data specified by the burner and boiler manufacturers electrical connection the electrical connection work comprising all the installation materials terminals and earth connections must be carried out in accordance with the applicable regulations for the electrical installation of the burner care must be taken to observe the circuit diagram made out for the furnace system the electrical connection of the burner and gas valves and instruments shall be entrusted to authorized specialists only note for the installation of the connection cables care must be taken to provide cable loops of sufficient length to allow for the swing-out of the boiler door and burner make sure after the completion of the electrical connection work to check the wiring of the electrical system of the burner this should also include a check of the direction of rotation of the fan and oil pump motors boiler inspection glass cooling for cooling and cleaning the boiler inspection glass a cooling line e.g hose may be installed from the burner to the inspection glass the burner is provided with a connection socket for this purpose electric ignition nozzle rod 13

[close]

p. 14

installation gas connection gas connection the gas lines and valves and instruments group should be installed and taken into operation in accordance with the applicable engineering standards and regulations gas properties prior to any installation work make sure to obtain the following data from the gas supply company 1 2 3 4 type of gas gas family i ii iii calorific value hun=kw/m³ kj/m³ maximum co2 content of exhaust gas gas connection pressure and rest pressure gas connection pressure a minimum connection pressure must be available upstream of the burner gas valve to ensure the proper functioning of the burner for the installation of the valves and instruments group take care to observe the mounting instructions supplied by their manufacturers these are packed with the equipment the gas line installed to the burner must be dimensioned in accordance with the throughput rate and the available pressure for selecting the nominal bore dn of the gas valves and instruments group care should be taken to observe the flue resistance of the boiler and the gas pressure loss of the burner and valves and instruments group gas valves and instruments group the gas valves and instruments group can be connected directly to the gas feed line take care to observe the correct order of installation and direction of flow arrow on housing check the valves and instruments and connection pieces for absence of dirt particles and foreign matter before installation and initial operation to provide effective conditions for start-up make sure the distance between the burner and the gas stop valve is as short as possible leak test the gas line upstream of the burner gas valves and instruments group must be installed in accordance with the applicable regulations checked for absence of leaks vented and certified accordingly by the gas installation company the screwed unions and flanged joints must be checked for proper tightness by making a pressure test the leak test must be made under pressure using approved foaming agents which do not cause corrosion for steam boiler furnaces the result of the leak test must be duly certified venting prior to taking the burner into operation or after any repair work make sure to vent the complete gas feed line and the gas valves and instruments group into the open atmosphere e.g by means of a hose taking care to avoid any hazards in no case should the gas line be vented into the heating or furnace chambers make use of a test burner to check the gas-carrying spaces are free from an inflammable gas mixture support the valves and instruments group must be supported with a telescopic jacking member or similar during and after installation e.g on filter and valve joint it is recommended to provide an easyto-disconnect joint with planar sealing faces to facilitate repair work on the boiler furnace and allow the boiler door to be swivelled out if required type of gas test prior to mounting the burner to the gas feed line check the available type of gas and burner type against the data given on the burner nameplate attached to burner be sure the description of the burner and the type of gas are the same as indicated on the nameplate g natural gas 14

[close]

p. 15

installation oil connection oil pressure control feed oil connection hoses are used for connection to the oil lines and stop valves the hoses must be installed according to the applicable standards relieved of tensile load free of distortion to avoid kinking and exclude the danger of breakage take care when mounting the oil lines to bring their ends as close to the burners as possible and to arrange them in a way that the boiler door and the burner can be swung out without any obstrucrange of application of oil hoses burner type ek 6.240 ek 6.300 dn 20 20 lenght [mm 1500 1500 2 connection on both ends r 1/2 r 1/2 minimum bending radius [mm 230 240 oil pressure control feed the feed pressure is controlled by means of the pressure regulator installed in the pump and should be set at approx 25 to 30 bar depending on burner output and nozzle make the pressure regulator is operated by turning its screw make sure to fill the pump with oil prior to taking into operation pump bleeding open the feed and return stop valves and ensure the ring line if any is in operation reduce the oil pressure at the pressure regulating valve turn on the pump by pressing the contactor check the pump for proper direction of rotation check for proper oil delivery and absence of leaks in the hydraulic oil system for bleeding the pump open the pressure gauge connection for example when taking the burner into operation proceed by gradually increasing the pressure to operating level 2530 bar checking the pressure oil suction pressure the maximum permissible vacuum is 0.2 bar at higher vacuum levels the fuel oil will tend to gas evolution which may lead to operating trouble in the ring line mode of operation the pump oil pressure is not allowed to exceed 5 bar tion refer to the technical documentation for the line dimensions for the feed and return lines from the stop valves to the tank oil filter a filter must be installed upstream of the pump to protect the oil pressure pump and the hydraulic system installation options · two-line installation separate feed and return lines without delivery pump · ring line system with delivery pump and gas-air separator 1 instrument mounting prior to adjusting the burner make sure to mount the test pressure gauges for measuring the feed pressure item 2 and return pressure item 1 a vacuum gauge and pressure gauge are mounted to the oil pump for measuring the oil pressure note after the burner has been taken into operation the gauges must be removed again and the connections sealed with suitable means if the gauges are mounted to remain on the burner they should be fitted with stop valves 15

[close]