p. 1

operation manual for the authorized specialist dual-fuel burner ek 6 7 8 9 gl-euf 01/2006 102.882.9856

[close]

p. 2

overview inhalt overview overview operation functioning operation start-up installation installation start-up start-up start-up adjusting instructions start up adjusting instructions adjusting instructions adjusting instructions adjustment gas valves and instruments group adjustment adjustment servicing instructions 2 important information 4 warranty 4 product description 4 technical data sheet monoblock dual-fuel burne 5 dimensioned drawings 9 dimensioned drawings 10 start-up mode oil operating mode general safety functions 12 gas starting function 13 gas operating function 13 fuel-air compound control gas valves and instruments group 14 hydraulic diagram l-e gl-e burner ek 6 ek 9 15 hydraulic valves and instruments group 16 burner head settings 17 mounting to boiler electrical connection presetting 20 boiler lining 21 burner gl-ruf/euf 21 gas connection 22 oil connection oil pressure control feed 23 return nozzle rod type rdn burner type ek 6 24 nozzle selection type w1 50° 25 return nozzle rod rdg 1250 26 nozzle selection sonic 27 checking procedure 28 gas pressure gas/air flow rate adjusting procedure 29 gas ignition pilot burner 30 fan for gas ignition/pilot burners 31 types skg 200-2 and skg 226-2 31 elektronic burner control with electronic compound controller 34 flame detecting system type flw 05 35 servomotor type sad 15.0 36 electrical actuator stm 40 37 starting the bcs etamatic vms/fms electronic compound controller 38 oil pressure switch air pressure switch 39 gas pressure switch 40 function automatic combustion controller type lfl 1 lgk 16 41 controller type ks 92 41 flame monitor 42 sensor current detector 42 description 43 basic construction 44 gas pressure regulator 45 double solenoid valve type dmv-d 47 gas filtersafety vent valve 48 combined ignition gas controller 49 fan impeller 50 burner maintenance 51 exhaust gas test 52 trouble shooting instructions 53 operating trouble 55 system diagram 56 2

[close]

p. 3

overview important information warranty product description important information the burners of type ek 6 7 8 9 gl-euf 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 ek 7 ek 8 ek 9 gl-euf 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 actuator for the air dampers oil pressure-atomizer with high-pressure 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 note it is recommended before changing over the burner from oil to gas mode to take precautions for preventing the oil in the nozzle and nozzle rod from coking if the burner is operated in gas mode for a longer period make sure to empty the nozzle rod before start-up 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 3

[close]

p. 4

technical data sheet technical data sheet monoblock dual-fuel burne monoblock dual-fuel burner ek 6.240 300 gl-euf low-nox with free flame-mixing unit low-nox with free flame-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor flame detector fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 6.240 300 gl-euf 6.240 g 6.240 l 6.300 g 6.300 l 6.240 gl-euf 400 2780 kw 55 235 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb 35 170 kg 6.300 gl-euf 439 3119 kw 75 263 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 4,0 kw 8,5 a 2800 min-¹ smg 16026 1,1 kw 735 l/h 30 bar rdn thread 7/8 dn 20 x 1500 r 1/2 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 za20 140 zm20-14 and ebi zb 35 170 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 25 20 15 10 5 0 0 500 1000 1500 2000 2500 3000 3500 qf burner output [kw 03/05 no 4

[close]

p. 5

technical data sheet technical data sheet monoblock dual-fuel burner monoblock dual-fuel burner ek 7 gl-euf low-nox with free flame-mixing unit low-nox with free flame-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor flame detector fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 7 gl-euf 7.350 g 7.350 l 7.450 g 7.450 l 7.350 gl-euf 630 4410 kw 65 372 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 5,5 kw 11,7 a 2800 min-¹ kl-ta 4 c 2,2 kw smg 19065 1,5 kw 850 l/h 900 l/h 30 bar rdg 1250 thread m14 sonic dz -rlf dn 20 x 1500 r 3/4 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 and ebi zb 35 310 kg 7.450 gl-euf 790 4993 kw 73 421 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 7,5 kw 15,5 a 2800 min-¹ kl-ta 5 c 2,2 kw smg 1629 2,2 kw 1200 l/h 30 bar rdg 1250 thread m14 sonic dz -rlf dn 20 x 1500 r 3/4 dn 80 pn 16 dn 80 d 40-80 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 and ebi zb 35 320 kg air temperature 20°c test values according to en 676 and 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 5

[close]

p. 6

technical data sheet technical data sheet monoblock dual-fuel burner monoblock dual-fuel burner ek 8 gl-euf low-nox with free flame-mixing uni low-nox with free flame-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor flame detector fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 8 gl-euf 8.550 g 8.550 l 8.700 g 8.700 l 8.550 gl-euf 900 5930 kw 135 500 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 11 kw 22,5 a 2800 min-¹ kl-ta 5 c 2,2 kw smg 1629 2,2 kw 1200 l/h 30 bar rdg 1250 thread m14 sonic dz -rlf dn 20 x 1500 r 3/4 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 and ze30-7,5 zb 50 400 kg 8.700 gl-euf 1090 7730 kw 132 652 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 15 kw 30 a 2800 min-¹ kl-t 3 c 3,0 kw smg 1630 3,0 kw 1700 l/h 30 bar rdg 1250 thread m14 sonic dz -rlf dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 and ze30-7,5 zb 50 430 kg air temperature 20°c test values according to en 676 and en 267 din 4787 at 171 m above sea level pressure in combustion chamber [mbar 30 25 20 15 10 5 0 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 qf burner output [kw 03/05 no 6

[close]

p. 7

technical data sheet technical data sheet monoblock dual-fuel burner monoblock dual-fuel burner ek 9 gl-euf low-nox with free flame-mixing uni low-nox with free flame-mixing unit technical data burner output fuel flow rate operating mode type of fuel burner control box flame sensor flame detector fan motor pump unit gear output pressure nozzle rod nozzle oil hoses external connection gas connection gas inlet butterfly valve actuator ignition transformer ignition burner weight operating range ek 9 gl-euf 9 850 g 9 850 l 9.1000 g 9.1000 l 9 850 gl-euf 1350 9000 kw 155 760 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 18,5 kw 35 a 2800 min-¹ kl-t 4 c 4,0 kw smg 1631 4,0 kw 2250 l/h 2200 l/h 30 bar rdg 1250 thread m14 sonic dz -rlf dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 and ze30-7,5 zb 50 530 kg 9.1000 gl-euf 1400 11000 kw 185 930 kg/h fully modulating natural gas and light oil el bcs lgk 16 ffs06 f151 bcs f151e lgk 400 690 v 50hz 22 kw 42,5 a 2800 min-¹ kl-t 4 c 4,0 kw smg 1631 4,0 kw 2250 l/h 2200 l/h 30 bar rdg 1250 thread m14 sonic dz -rlf dn 25 x 1500 r 1 dn 150 pn 16 dn 150 d 80 150 mm sad 15 stm 40 mm1004 ea2 za20 140 zm20-14 and ze30-7,5 zb 50 570 kg air temperature 20° test values according to en 676 and en 267 din 4787 c at 171 m 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 no 7

[close]

p. 8

overview dimensioned drawings ek 6 gl-euf ek 6.240/300 gl-euf ignition gas connection tube 12x1 dimensions in boiler connection plate 8

[close]

p. 9

overview dimensioned drawings ek 7 8 gl-euf ek 7.350/450 gl-euf ignition gas connection tube 12x1 dimensions in boiler connection plate ek 8.550/700 gl-euf ignition gas connection tube 12x1 dimensions in boiler connection plate 9

[close]

p. 10

overview dimensioned drawings ek 9 gl-euf ek 9.850/1000 gl-euf ignition gas connection tube 12x1 dimensions in boiler connection plate 10

[close]

p. 11

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 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 oil control steepless full load gas control steepless full load vollast vollast betriebsstellung tellung load regulator operating position operating position load regulator release betriebsstellung leistungsregulierung freigabe startlast teillast leistungsregulierung regulierung release freigabe partial load start load partial load teillast zündung/ventile eignition/valves pump pumpe ignition gas valves gasventile zündung ein ein on off aus aus on ein off aus 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 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 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 11

[close]

p. 12

functioning gas starting function gas operating function gas starting function if there is a demand for heat by the furnace system the burner control circuit will be closed and the program flow started at the end of the program flow 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 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 fullload 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 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 gas section din trd 155 air luft 152 low-pressure 141 147 313 154 153 143 for trd nur bei only trd 313a 150 100 141 142 gas 144 dp 314 349 120 air luft 349 high-pressure 147 141 142 145 144 148 143 100burner 120air damper 141ball valve 142gas filter 143pressure gauge with stop valve 144gas pressure regulator 145safety stop valve 147test burner with stop valve optional 148safety vent valve 150gas control damper 153main gas solenoid valve 154safety solenoid valve 155combined ignition gas unit or single components 313minimum gas pressure switch 313amaximum gas pressure switch 314leak test 349actuator 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 items 153 154 can also be provided as double valves up to dn 125 gas l 10 x Ød 12

[close]

p. 13

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 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 electronic compound control the air box includes an actuator for operating the air damper the oil control valve incorporates an actuator for adjusting the return oil flow rate and thus the output of the burner an actuator is also mounted to the gas damper for varying the gas throughput rate the actuators for the air and fuel flow control will be operated depending on output by the electronic compound control which will move them into the programmed positions 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 note use should only be made of gas valves and instruments that have been approved in accordance with the burner test specifications electronic compound control 1a m 2 3 gas oil vl Ölfeed 1b m oil return Ölrl 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 13

[close]

p. 14

operation hydraulic diagram l-e gl-e burner ek 6 ek 9 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 143 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 pi 175 176 vl 312 178 178 180 187 a 181 120 349 m 184 311 m 349 pi 143 181 rl 14

[close]

p. 15

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 15

[close]