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operation manual for the authorized specialist dual-fuel burner e 10 gl-e 09/2008 14 012 365 rev a

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overview Übersicht contents inhalt overview contents 2 important information warranty safety instructions 3 safety instructions installation start-up maintenance 4 5 important components 5 burner description 6 operation fields 7 gas pressure loss burner head 8 gas pressure loss gas butterfly 8 mounting to boiler electrical connection presetting 11 burner head settings eh 24 12 burner head settings rdg 1250 13 ignition electrode settings 14 gas connection 15 gas train description 16 oil system diagram 18 oil connection oil pressure control feed 19 hydraulic diagram 20 checking procedure 21 disassembling firing head 22 oil start-up mode oil operating mode general safety functions 24 gas starting function gas operationg function 25 fuel-air compound control 26 electronic burner controller 27 servo motor type sad 15 electrical actuator stm 40 28 flame sensor 29 hydraulic valves and instruments group 30 return nozzle rod rdg 31 nozzle rod linkage 24 eh 32 nozzle plate throughput characteristic for 24-eh 35 nozzle selection sonic 36 oil pressure switch air pressure switch 37 gas pressure switch 38 adjustment combination controls cg 15 -30 39 exhaust gas test 41 burner maintenance 43 fan impeller 44 cause and removal of disturbance 45 47 technical data installation startup servicing instructions trouble shooting instructions manufacturer s declaration 2 09/2008 14 012 365 rev a

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overview important information warranty safety instructions general information these operating instructions are a fixed component of the system which should be displayed in a prominent location at the point of installation of the heat generator and should include the address and telephone number of the nearest customer service centre they are directed solely at authorised expert personnel these operating instructions contain the most important information for installing commissioning and maintaining the burner safely and must be observed by any personnel who work on the system original parts should only be exchanged by a duly qualified specialist place of installation the burner must not be operated in rooms containing corrosive vapours e.g spray perchloroethylene hydrocarbon tetrachloride solvent etc or tending to heavy dust formation or high air humidity adequate ventilation must be provided at the place of installation of the furnace system to ensure a reliable supply with combustion air 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 en 267 gas burners with blowers forced draught oil burners 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 important information the burners are designed in accordance with the specification in the technical data section alternative fuels on request 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 authorised specialist should be entrusted with the installation of the gas system and all applicable directives and regulations must be observed 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 the operator must in accordance with country-specific standards and legislation be given instruction on how the heating installation operates national requirements and building regulations must be taken into consideration during installation of a gas-fired system national requirements and building regulations must similarly be taken into consideration during installation of an oil-fired system 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 guarantee the guarantee does not cover damage resulting from failure to commission and maintain the burner in accordance with the operating instructions damage or loss arising from incorrect installation damage or loss arising from incorrect adjustment damage or loss arising from unauthorised tampering and damage or loss arising from improper operation e.g operating the system at excessive pressure subject to change without notice due to ongoing technical developments safety instructions the burner has been built and tested to applicable standards and directives and recognised rules of technical safety and depending on the burner type has either been type tested see declaration of conformity in the technical data section or must be tested individually see manufacturer s declaration in the technical data section risks to persons or property may arise if the burner is not operated correctly or used for its intended purpose to eliminate these risks the burner may only be installed and operated · in accordance with its intended purpose · in a technically safe condition · in compliance with all guidelines and information contained in these operating instructions · in compliance with all inspection and maintenance guidelines as specified in the operating instructions or components documentation or as defined by applicable national legislation standards or requirements 3 all safety devices of the system must be checked on a regular basis as specified by applicable regulations 4 protective clothing must be worn while work is being carried out on the system 5 the information in the operating instructions must be observed as well as the applicable requirements or regulations of accident prevention and relevant national construction and safety regulations requirements standards and legislation safety measures and rules of conduct 1 burner only to be operated in an undamaged defect-free and technically safe condition 2 assembly commissioning adjustments repair and maintenance carried out only by experts trained and authorised for the work concerned this also applies to work on the electrical system and the gas/oil supply 09/2008 14 012 365 rev a 3

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overview important information safety instructions installation start-up maintenance 6 the markings on the system must be maintained in a clearly readable condition and restored if necessary 7 equipment to be operated only with safety devices activated and in good working order 8 the system must be checked annually ­ or more frequently if necessary depending on system conditions for externally visible damage and for the correct operation of safety devices 9 safety functions and safety times must not be impaired rendered inoperational or modified by additional external wiring tasks carried out on the electrical system · all tasks involving the electrical system must be carried out by expert electricians · before any work is carried out the system must be disconnected from the power supply and secured against unexpected reconnection · work on live systems may only be carried out under the supervision of a second person who would be able to disconnect the power supply in the event of danger · the electrical system must be routinely checked as part of maintenance damage of any kind e.g loose connections damaged cable insulation must be rectified immediately safety instructions for maintenance · the operator must be informed of all work to be carried out before it begins · assembly commissioning adjustments repair and maintenance carried out only by experts trained and authorised for the work concerned this also applies in particular to work on the electrical system and the gas oil supply · protective clothing must be worn while work is being carried out on the system · specified adjustment maintenance and inspection work must be carried out at the specified intervals · before any work is carried out on the system the system must be disconnected from the power supply and secured against unexpected reconnection · the fuel supply must be closed before work is carried out on the system · all safety devices of the system must be checked on a regular basis as specified by national requirements regulations standards and legislation · damaged system parts must be replaced immediately if parts are to be replaced it is only permitted to use genuine parts or replacement parts that have been approved or authorised by the manufacturer · the installation of additional components that were not subjected to model series or individual testing at the same time as the system is not permitted · do not modify the system or fit attachment or conversion parts without the authorisation of the manufacturer · loose connections must be checked for firm seating after they have been reconnected · if seal connections are opened the sealing surfaces must be cleaned thoroughly at the time of reassembly ensure a perfect connection damaged seals must be replaced with 09/2008 14 012 365 rev a safety instructions for assembly always disconnect the system from the power supply before assembly work begins switch off the master and emergency switches and secure them against the possibility of being switched back on danger failure to comply could result in a harmful or fatal electrical shock risk of severe injury and danger of death safety instructions for initial commissioning the initial commissioning of the heating installation must only be carried out by the constructor manufacturer or another of the experts described all regulating control and safety devices must be checked for correct operation and ­ where adjustment is possible ­ for correct adjustment before initial commissioning it is necessary to check electrical circuits for correct fusing and the measures for protection against accidental contact with electrical equipment and wiring new ones check for leaks once reassembly is complete · repairs to limiting devices automated equipment flame monitoring equipment and other safety devices must only be carried out by the manufacturer or its appointed representatives the expert charged with carrying out maintenance work must replace complete components or assemblies with those of the same type · safety devices must be checked for correct operation following their replacement or repair and after any maintenance work has been completed · only use the burner with furnaces that are suitable for the flame dimension concerned i.e in which the flame may burn out unhindered · any change to the furnace pressure e.g as a consequence of modifications to the flue system and any modification that would result in a change in the supply of air to the burner e.g a retrofitted soundproofing shroud requires reconfiguration of burner regulation · persons present in the proximity during burner operation must be equipped with suitable measures for protection against harmful noise levels after all maintenance and repair work 1 function test 2 at all load points check o2 co2 co nox values soot emissions and exhaust gas losses 3 create a measurement report leave a copy with the system 4

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technical data important components burner type combustion power output fqe=frequency converter for motor externally e10.12000.30 gl-e natural gas 1.300 12.000 kw 1750 kw without fqe e10.12000.37 gl-e natural gas 1.300 12.000 kw 1750 kw without fqe fuel oil el 3.600 12.000 kw 1:9,2 for natural gas e and with fqe 1:6,8 for natural gas e without fqe 1:3,5 for fuel oil el deviating values on request fuel oil el 3.600 12.000 kw max control ratio n.b the lower operating point must also be within the working field ring line pressure max 2 bar boiler furnace pressure fuels operation type electronic air-fuel-compound-control automatic firing device electrotechnical equipment optional electrotechnical equipment selection of the nominal burner capacity within the nominal capacity area marked in the working field deviating nominal capacities on request natural gas e ll fuel oil el to din 51603-1 or equivalent continuously modulating etamatic oem or bcs 300 on burner alternative electronic burner controls in separate cabinet attached to the burner is an ip54 control cabinet that contains the terminal block and where applicable the combustion manager and other components bcs or etamatic oem as burner controller power controller with protection soft start or y-d start externally in a separate control cabinet power regulation by external 4-20 ma nominal value input frequency converter externally in a separate control cabinet preparation for controller-specific o2 regulation probe fitted externally profibus dp modbus rt ethernet 400/690 v 50/60hz /2950 u/min ip55 30 kw 37 kw dn100 pn16 natural gas e pmin=250 mbar natural gas ll pmin=300 mbar on burner m 38x1,5 external 1 oilhose dn 25x1500 high pressure pump 30 bar mounted on burner approx 2700 l/h 4,0 kw ip40 optional ip54 gas operation 100-150 mg/kwh air-free to en 676 actual values on request fuel-oil operation 200-250 mg/kwh air-free to en 267 precise values on request 6,2 m min 1,3 m depending on combustion output and nox requirements fan motor gas connection oil connection oil pump protection class nox-emissions flame length max at 3 o2 flame diameter acoustic emissions sound pressure site ambient temperature including impact of heat radiation 97 dba acoustic pressure average value on enveloping surface at 1 m distance closed rooms or weatherproof on site non-aggressive atmosphere 0°c 60°c with bcs or etamatic on burner -10°c 60°c with alternative electronic burner controls in switch cabinet relative humidity max 60 special corrosion protection on request approx 650 kg plus 100 kg for transport rack qra 2 qra 53 ffs 06 zm 20-14 optional za 20 140 and ebi 2-pole 09/2008 14 012 365 rev a 5 burner weight important components flame monitor ignition transformer

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technical data important components burner description burner type servo motor air pressure switch nozzle rods oil pressure switch oil pump e10.12000.30 gl-e sad 15 stm 30/40 dl 50a rdg 1250 24 eh dsb 158 f931 smg 1631 4,0 kw 2200 l/h e10.12000.37 gl-e operating mode the burner is designed as an automatic continuously controllable dual-fuel blast burner for the alternative operation for light oil el according din 51603-1 or technical fuel gases according en 437 gasfamily 2 and 3 tested to en 267 and 676 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 bcs and etamatic oem design the burner is equipped with an electronic burner control system automatic furnace controller electronic compound controller gas valve leak detector other electronic burner controller electronic burner control automatic furnace controller electronic compound controller gas valve leak detector is placed in the seperated switch cabinet 6 hydraulic components a separate pump unit is mounted to the burner hydraulic components installed on the burner 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 possibly frequency converter sensors monitoring of the main flame by a flame sensor and an approved automatic furnace controller differential pressure switch is fitted for fan air monitoring a speed control system is used ignition oil mode direct electrical high voltage ignition on reduced burner load max allowed ignition load is less than 35 of burner power output gas mode electrical high voltage ignition of the enclosed ignition burner heat capacity of the ignition flame 10 of the main flame 09/2008 14 012 365 rev a

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technical data operation fields operation fields e10.12000 g-le according en 267 and 676 40 35 boiler furnace pressure [mbar druck im feuerraum [mbar e10.12000.37 gl-e fqe e10.12000.37 gl-e e10.12000.30 gl-e fqe 30 25 20 15 10 5 0 0 2 4 6 8 10 12 fuel oil basic load limit full load range e10.12000.30 gl-e 14 combustion power output [mw fqe=frequency converter for motor externally feuerungsw ärmeleistung [mw 09/2008 14 012 365 rev a 7

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technical data gas pressure loss burner head gas pressure loss gas butterfly druckverluste gas mischeinrichtung e10 gle pressure loss gas mixed unit e10.12000 gl-e 70 60 50 pressure loss [mbar druckverlust [mbar 40 30 20 10 0 700 800 900 1000 1100 3 1200 1300 1400 1500 operation volume flow natural gas [m /h 15°c 1013 mbar dv 0,61 volum enstrom erdgas [m ³/h 15°c 1013 m bar dv 0,61 t 1013 dv p p diagr 288 p 0 61 pressure bei voll gas butterfly full100 typ dkg bvg typ dkg bvg druckverlust loss geöffneter gasklappe dn open dn 100 100 Ø 65 Ø 80 Ø 100 pressure loss [mbar druckverlust mbar 10 1 100 1000 10000 operation volumenstrom v [m³/h [m3/h erdgas 15°c dv mbar volume flow natural gaserdgas 15°c 1013 mbar,1013 0,62 dv 0,62 8 09/2008 14 012 365 rev a

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technical data dimensional drawing e10.12000 gl-e the cover of motor is removable in case of opening boiler door for revision drilling template motor with disassembled protection grid 09/2008 14 012 365 rev a 9

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technical data installation conditions 1 zu 1 boiler lining a=t 350 standard muffle depth d 497 d1 525 optional extensions dimension a primarily use the modular grid of 100 mm three-pass boilers a=t a=t-20 80 permissible u-fired boilers a=t+50 mm+u-fired column front reversing chamber the burner lining must be installed at right angles to the burner tube possible trimming work bevelling rounding as is required for reversing boilers for example should done at a diameter not below 70 of the combustion chamber diameter 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 2 1480 ad 2 advice for maintainance instead of hinging the air box is can be remove completly minimum distance on double flame tube boilers 3 ad 3 note in special cases the air intake box can be mounted in a way that the opening shows to another direction the dimensioned drawing will the differ slightly the air intake box can be rotated in steps of 22,5 ° the swivelling function however is then not functional 10 09/2008 14 012 365 rev a

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installation mounting to boiler electrical connection presetting check before burner installation check the mixing unit for correct setting see dimensioned drawing deviations from the burner head adjustment data may be acceptable following a type test or individual testing by arrangement with the test authority in order to adapt the burner to the boiler and flue gas system however these deviating adjustments must be carried out by an authorised expert and all modified dimensions must be documented in the adjustments and measurements log containing the flue gas measurement and combustion stability evaluation this must be handed over to the test authority on request set the ignition electrodes according to the sketch check the burner pipe mounting according to section boiler lining for burners and the boiler manufacturer s specifications burner plate with gasket strip attention after the completion of the electric connection work make a check of the wiring of the burner electric system this includes a check for the direction of rotation of the burner motor fan boiler inspection glass cooling for cooling and cleaning the boiler inspection glass a cooling line e.g a hose may be installed from the burner to the inspection glass a connection piece is provided on the burner for this purpose arrangement of sealing tape on the boiler 1 evenly stick on self-adhesive tape 2 according to figure adapt the flat gasket by cutting to the boreholes in the area of the four vertically arranged boiler fastening holes 3 in case of butt joints make sure the bordering is fitting closely 4 electric connection the electric connection including all installation materials as well as joints and earth terminals must be made in accordance with the applicable regulations for the electrical installation of the burner reference should be made to the circuit diagram of the furnace system the electric connection of the burner and gas valves and instruments is allowed to be entrusted to authorized specialists only burner installation for mounting the burner to the boiler make sure the connection plate is prepared in accordance with the dimensions given in the technical datasheets · install the stud bolts in the connection plate · put the insulating base and burner in place and fasten with bolts 09/2008 14 012 365 rev a 11

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installation burner head settings eh 24 12 e 10.12000 g-le outer nozzles turned in pairs 45° 09/2008 14 012 365 rev a section view x fit the inner nozzle into the swirl

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installation e 10.12000 g-le outer nozzles turned in pairs 45° burner head settings rdg 1250 09/2008 fit the inner nozzle into the swirl 14 012 365 rev a 13

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installation ignition electrode settings adjustment dimensions for ignition electrodes in pilot burner 14 09/2008 14 012 365 rev a

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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 the connection between the gas distribution network and the gas ramp must be done by authorised persons the section of the pipings must be calculated so that the loss of load doesn t exceed 5 of the distribution pressure a quarter turn manual valve not supplied must be provided for upstream of the gas ramp and the filter the filter must be installed on a horizontal nozzle with the cover in the vertical position to enable cleaning the threaded unions used must be in conformity with present standards tapered male thread straight female thread with sealing provided in the thread provide for sufficient space to access the gas pressure switch adjustment 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 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 caution 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 caution the absence of impurities and foreign bodies must be checked before installation and commissioning of the gas ramp the lever valves and unions 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 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 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 calorific value hun=kw/m³ kj/m³ maximum co2 content of exhaust gas gas connection pressure and rest pressure 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 09/2008 14 012 365 rev a 15

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