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operation manual for the authorized specialist oil burner ek 6 7 8 9 l-r 01/2006 102.880.8617

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overview inhalt contents overview overview contents 2 important information warranty product description 3 technical data 4 dimensioned drawings 9 start-up mode oil operating mode general safety functions 12 fuel-air compound control hydraulic diagram 13 hydraulic diagram l-r gl-r burner ek 6 9 14 hydraulic valves and instruments group 15 burner head settings 16 mounting to boiler electrical connection presetting 19 boiler lining for burner l-r/e 20 oil connection oil pressure control feed 21 return nozzle rod type rdn burner type ek 6 22 nozzle selection type w2-50° 23 return nozzle rod rdg 1250 burner ek 7 ek 9 24 nozzle selection sonic 25 checking procedure 26 oil/air flow rate adjustment 27 electrical actuator limit switch setting 28 oil pressure switch option air pressure switch 29 automatic furnace controller lal lok regulator ks 92 30 flame monitor sensor current measurement 31 fan impeller 32 burner maintenance 33 exhaust gas test 34 trouble shooting instructions 35 operating trouble 37 system diagram 38 konformitätserklärung 39 operation operation start-up installation installation start-up start-up start-up adjusting instructions adjusting instructions operation adjusting instructions adjustment servicing instructions 2

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overview important information warranty product description important information the burners of type ek 6 7 8 9 l-r have been designed for the combustion of light fuel oil el the burners should be installed and taken into operation by qualified personnel only who will be responsible for the proper performance of this work in accordance with the applicable regulations and guidelines any repair work on monitors limiters and automatic furnace controllers and on the other safety facilities are allowed to be done 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 en267 din4787 vde 0116 oil atomizer burners electrical equipment of furnace place of installation the burner must not be operated in rooms containing aggressive 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 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 7 8 9 l-r have been designed for the combustion of light fuel oil according din 51603-1 the burners are equipped with combustion air fan and air pressure switch with test key oil pressure atomizer with high-pressure oil pump nozzle rod with stop valve return nozzle and oil hydraulics block with pressure switches valves and control shaft pressure hoses electrical ignition system and mechanical compound control system according to din 4755 the user must be instructed in the operation of the burner 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 3

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technical data sheet technical data monoblock oil burner ek 6.170 200 l-r ek 6.170 200 l-r technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor 6.170 l-r 501 1800 kw 42 152 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50hz 3,0 kw 6,4 a 2800 min-¹ smg 1945 0,75 kw 6.200 l-r 640 2300 kw 54 194 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50hz 3,0 kw 6,4 a 2800 min-¹ smg 1945 0,75 kw pump unit gear output pressure nozzle rod nozzle oil hoses external connection actuator ignition transformer weight operating range ek 6.170 200 l-r 520 l/h 30 bar rdn thread 7/8 dn 16 x 1500 r 1/2 sqm 10/11 stm 30/40 za20 140 zm20-14 150 kg 520 l/h 30 bar rdn thread 7/8 dn 16 x 1500 r 1/2 sqm 10/11 stm 30/40 za20 140 zm20-14 150 kg 6.170 l 20 6.200 l air temperature 20°c test values according to en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 18 16 14 12 10 8 6 4 2 0 0 500 1000 1500 2000 2500 qf burner output [kw 03/05 no 102.881.0151 4

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technical data technical data sheet monoblock oil burner ek 6.240 300 l-r technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor 6.240 l-r 681 2500 kw 57 210 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 6.300 l-r 940 3250 kw 79 280 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw pump unit gear output pressure nozzle rod nozzle oil hoses external connection actuator ignition transformer weight operating range ek 6.240 300 l-r 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 sqm 10/11 stm 30/40 za20 140 zm20-14 160 kg 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 sqm 10/11 stm 30/40 za20 140 zm20-14 160 kg 6.240 l 25 6.300 l air temperature 20°c test values according to en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 3500 qf burner output [kw 03/05 no 102.881.0195 5

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technical data technical data sheet monoblock oil burner ek 7 l-r technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor 7.350 l-r 1115 4500 kw 94 380 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50 hz 5,5 kw 11,7 a 2800 min-¹ kl-ta 4c 2,2 kw smg 19065 1,5 kw 800 l/h 900 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 sqm 10/11 stm 30/40 za20 140 zm20-14 250 kg 7.450 l-r 1300 5300 kw 110 447 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50 hz 7,5 kw 15,5 a 2800 min-¹ kl-ta 5c 2,2 kw smg 1629 2,2 kw 1200 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 sqm 10/11 stm 30/40 za20 140 zm20-14 250 kg pump unit gear output pressure nozzle rod nozzle oil hoses external connection actuator ignition transformer weight operating range ek 7 l-r 30 7.350 l 7.450 l air temperature 20°c test values according to en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 1000 2000 3000 4000 5000 6000 qf burner output [kw 03/05 no 102.870.2645 6

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technical data technical data sheet monoblock oil burner ek 8 l-r technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor 8.550 l-r 2000 6049 kw 168 510 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50 hz 11 kw 22,5 a 2800 min-¹ kl-ta 5c 2,2 kw smg 1629 2,2 kw 1200 l/h 30 bar rdg 1250 thread m14 dn 20 x 1500 r 3/4 sqm 10/11 stm 30/40 za20 140 zm20-14 320 kg 8.700 l-r 2000 7672 kw 168 647 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50 hz 15 kw 30 a 2800 min-¹ kl-ta 3c 3,0 kw smg 1630 3,0 kw 1700 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 sqm 10/11 stm 30/40 za20 140 zm20-14 350 kg pump unit gear output pressure nozzle rod nozzle oil hoses external connection actuator ignition transformer weight operating range ek 8 l-r 8.550 l 30 8.700 l air temperature 20°c test values according to en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 qf burner output [kw 03/05 no 102.870.2634 7

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technical data technical data sheet monoblock oil burner ek 9 l-r technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor fan motor 9 850 l-r 2574 9596 kw 217 809 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50 hz 18,5 kw 35 a 2800 min-¹ kl-t 4c smg 1631 4,0 kw 2250 l/h 2200 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 sqm 20/21 stm 30/40 za20 140 zm20-14 450 kg 9.1000 l-r 2490 11409 kw 210 962 kg/h fully modulating light oil el lal 2.2 lok 16 qrb 3 rar 7 400 690 v 50 hz 22 kw 42,5 a 2800 min-¹ kl-t 4c smg 1631 4,0 kw 2250 l/h 2200 l/h 30 bar rdg 1250 thread m14 dn 25 x 1500 r 1 sqm 20/21 stm 30/40 za20 140 zm20-14 490 kg pump unit gear output pressure nozzle rod nozzle oil hoses external connection actuator ignition transformer weight operating range ek 9 l-r 30 9.850 l 9.1000 l air temperature 20° test values according to en 267 din 4787 at 171 m c above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 2000 4000 6000 8000 10000 12000 q f burner output [kw 03/05 8 no 102.870.2521

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overview dimensioned drawings ek 6 l-r ek 6.170/200 l-r dimensions in boiler connection plate ek 6.240/300 l-r dimensions in boiler connection plate 9

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overview dimensioned drawings ek 7 8 l-r ek 7.350/450 l-r dimensions in boiler connection plate ek 8.550/700 l-r dimensions in boiler connection plate 10

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overview dimensioned drawings ek 9 l-r ek 9.850/1000 l-r dimensions in boiler connection plate 11

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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 burner control circuit will close and the program be started after the 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 electric actuator opens the closed air damper to its full-load position so that the burner will sweep the furnace compartment and exhaust ports at the required air flow rates shortly after the pre-ventilation process has been started the lack-of-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 the solenoid valves will open and thus allow the pressurized oil to flow to the oil control 2-stage sliding full load 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 startup 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 demand the electric actuator of the mechanical compound control system will be fed with the open or close signal via the regulator and thus increase or decrease the oil and air flow rates this compound control system will vary the positions of the oil control valve and air damper and thus regulate the oil flow rate in conjunction with the air flow rate the burner can either be controlled in two-stage sliding mode or if a respective controller is provided in stepless control mode 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 steepless full load vollast vollast operating position betriebsstellung operating position betriebsstellung load regulator load regulator leistungsregulierung release leistungsregulierung release freigabe teillast freigabe teillast partial load partial load ignition valves zündung/ventile pump pumpe ignition valves zündung/ventile pump pumpe ein aus ein aus general safety functions in case a flame does not develop when starting the burner fuel release the burner 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 pre-ventilation 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 12 on trouble with the automatic 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 upon voltage recovery there may be an automatic restart unless another interlock is provi ded e.g by the safety system in any case of trouble the fuel oil supply will be shut off right away the program unit will stop at the same time causing also the trouble location indicator to stop the symbols will indicate the kind of 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.

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operation fuel-air compound control hydraulic diagram 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 two-stage sliding control concept the partial-load and full-load positions are within the control range depending on the heat demand these two load points will be selected in sliding mode a larger fuel feed will not be suddenly turned on or off in the stepless control mode the load will be controlled at any point within the control range depending on the heat demand the two-stage sliding and the stepless control concepts are different only in the control systems used with the burners the same mode of operation is used for both versions mechanical compound control the compound control system will be operated by the steplessly reversible electric drive unit in dependence of the heat requirement the air damper and the oil control valve will be controlled by the same system in the burner operating mode a certain quantity of the oil not being burnt in the combustion process is returned from the nozzle via the oil control valve this return oil is regulated by an oil control valve which is operated in a linked concept with the air flow to ensure an optimum air-to-fuel adjustment over the full control range it will be possible to vary the position of the air damper by means of setscrews incorporated in the compound controller mechanical compound control oil feed oil return air 1 2 3 4 compound controller burner boiler combustion air fan 13

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operation hydraulic diagram l-r gl-r burner ek 6 9 hydraulic diagram -din en 120 air damper 143 pressure gauge option 175 filter 176 pump 178 feed solenoid valve 180 nozzle rod 181 return solenoid valve 184 output control valve 187a pressure regulating valve integrated in pump 311 return oil pressure switch 312 feed oil pressure switch 349 actuator 143 pi vl 175 176 312 178 178 180 187 a 181 120 184 pi m 143 349 181 rl 311 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 hydraulic diagram -trd 604/72 h 143 pi vl 175 176 312 178 178 180 187 a 181 120 184 m 349 181 rl 311 pi 143 14

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operation hydraulic valves and instruments group complete hydraulic valves and instruments group 3 1 2 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 2 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 basic module 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 depending on the level of equipment of the hydraulic system oil pressure switches and pressure gauges 3 may be installed in the supply and return pipes of the basic module 1 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 f 2523 is marked with a stamped arrow opposite to the direction of the oil flow from the nozzle rod back to the pump extension module control shaft installation 15

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