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dunphy TAD4, Operating Manual

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Operating Instructions For TD/TAD4 Dual Fuel Burner 

June 13                                                                   88 of 165                                                  TD/TAD4 Manual Rev 4 

30 

1 

JACKING SCREW 

FASHEX00150 

31 

2 

OIL ELECTRODE 

IGELEC00110 

32 

1 

OIL TUBE SUPPORT SPIDER 

GA12370 

33 

4 

SPLIT ELECTRODE BUSH 

GA8264 

34 

1 

ART1400 BURNER GUN 

GA21876 

35 

2 

POSITIONAL ELBOW 10-4L 10mm 

COMPAD00550 

36 

12 

1/4"BSP DOWTY 'BONDED' SEAL 

SEADOW00105 

37 

4 

1/4" BSP YORKSHIRE FTG. BRASS PLUG 

YORFIT00510 

38 

2 

SWIVEL ELBOW 10mm MSE 10-4 L 

COMPAD00505 

39 

1 

TWIN PORT SANDWICH BLOCK (INSIDE) 

GA9178A 

40 

2 

SANDWICH BLOCK INNER O-RING 

ORINGS00180 

41 

1 

SANDWICH BLOCK OUTER O-RING 

0RINGS01025 

42 

1 

TWIN PORT SANDWICH BLOCK (OUTSIDE) 

GA9178B 

43 

1 

MALE STUD COUPLING 10mm MMC 10-4 L 

COMPAD00485 

44 

5 

STANDPIPE ADAPTOR 10mm MSA 10-4 L 

COMPAD00535 

45 

3 

EQUAL TEES 10mm 10 L 

COMPAD00520 

46 

4 

MOTOR HANGER PLATE SPACER 

GA7961 

47 

1 

VARIOTRONIC OIL METERING VALVE ASSEMBLY 

GA16090 

48 

2 

1/4" MINI BALL VALVE 

VALOIL00110 

49 

2 

M5 COPPER WASHER 

COPWAS00025 

50 

2 

0 - 600 PSI PRESSURE GUAGE 

PRESGA00100 

51 

3 

MALE STUD COUPLING 10mm X 3/8" MMC 10-6 L 

COMPAD00490 

52 

4 

3/8"BSP DOWTY 'BONDED' SEAL 

SEADOW00100 

53 

2 

PRESSURE SWITCH ADAPTOR 

BANMAN00170 

54 

2 

1/4" COPPER WASHER 

COPWAS00075 

55 

1 

SAUTER HIGH OIL PRESSURE SWITCH

 

BAILEY HIGH OIL PRESSURE SWITCH 

PRESWI00570

 

PRESWI00700 

56 

1 

BRIDGE HANDLE 

CONTOL02285 

57 

2 

STANDPIPE ADAPTORS 10mm MSA 10-8 L 

COMAD00545 

58 

12 

1/2"BSP DOWTY 'BONDED' SEAL 

SEADOW00110 

59 

1 

1/2" LUCIFER OIL SOLENOID VALVE 

SOLOIL00360 

60 

3 

MALE STUD COUPLING 10mm x 1/2" MMC 10-8 L 

COMPAD00495 

61 

1 

3/8" BSP BANJO BOLT #7 x 70 

GA10382 

62 

1 

1/2" BSP BANJO BOLT #4 x 72 

GA10143 

63 

1 

MANIFOLD No. 4 WITH VALVE CLUSTER 

GA16780 

64 

1 

COPPER WASHER 3/8" 

COPWAS00100 

65 

1 

COPPER WASHER 1/2" 

COPWAS00110 

66 

1 

1"BSP 'HEAVYWEIGHT' BARREL NIPPLE 

PIPNIP01340 

67 

1 

DH1-1-CLOCKWISE ROTATION

 

DH1-2-CLOCKWISE ROTATION

 

DH1-1-ANTI-CLOCKWISE ROTATION

 

DH1-1-ANTI-CLOCKWISE 

PUMDUN01012

 

PUMDUN01010

 

PUMDUN01025

 

PUMDUN01020 

68 

1 

POSITIONAL ELBOW 3/4" x 1/2" 

CONELB00125 

69 

2 

OIL SOL VALVE LUCIFER 1/2" N/C 

SOLOIL00240 

70 

1 

OIL MANIFOLD No. 1 

GA16777 

71 

2 

1/2" BSP BANJO BOLT #3 x 54 

GA10125 

72 

1 

MOUNTING BRACKET FOR VALVE CLUSTER FITTET TO DH-1 

GA10190 

73 

1 

D.90 MOTOR BELL HOUSING 

GA05900 

74 

1 

PUMP COUPLING ASSEMBLY 

PUMZCP00665 

Summary of Contents for TAD4

Page 1: ...1 of 165 _________________________________________________________________________________________ DUAL FUEL BURNERS TD TAD4 GENERAL INFORMATION AND OPERATING MANUAL ...

Page 2: ...uctions For TD TAD4 Dual Fuel Burner June 13 2 of 165 TD TAD4 Manual Rev 4 Revision Table Rev No Description Date By 1 2 3 4 Emergency stop information added section 5 9 Exploded drawings revised section 11 6 6 13 R S ...

Page 3: ...urner The Company should be contacted for advice This provision also applies to the legislation of countries to which the burners may be exported Where equipment not of The Company s supply is used in conjunction with the burners reference should be made to specific instructions or regulations governing the installation and use of such equipment The Company gratefully acknowledges the permission o...

Page 4: ...ntilation requirements 24 3 Combustion Head Settings 26 3 1 High Low Burners 27 3 2 Modulating Burners 28 3 3 Modulating TD410 Burners Fitted With Low NOx Multi Pipe Gas Head 29 3 1 Modulating TD415 420 Burners Fitted With Low NOx Multi Pipe Gas Head 31 3 2 Modulating TD410 Burners Fitted With Low NOx Multi Pipe Gas Head Multi Oil 33 3 1 Modulating TD415 420 Burners Fitted With Low NOx Multi Pipe ...

Page 5: ...motors 76 7 6 6 Burner Commissioning 76 7 6 7 Combustion values and results 76 8 Burner Maintenance Schedule 77 8 1 Opening the Burner 77 8 2 Minor Maintenance 78 8 3 Major Maintenance 78 8 4 Dismantling and Re assembly of Burners 79 9 Faults and fault finding 81 9 1 Ratiotronic 6000 6006 81 10 Useful Information 82 11 Exploded Diagram Spare Parts List 85 11 1 Modulating Oil Modulating Gas Setup 8...

Page 6: ...136 12 3 7 100mm Ratiotronic Unibloc with pilot exploded diagrams and parts list 137 12 4 Butterfly Gas Valve 139 12 4 1 General Arrangement 139 12 4 2 Exploded Diagram 140 12 5 Siemens VGD20 and VGD40 Gas Valve Blocks 141 12 5 1 Siemens SKP actuators 145 12 6 VPS 504 Valve Proving System 151 12 7 Variotronic VT Oil Metering Valve 154 12 7 1 General Description 154 12 7 2 Construction 154 12 7 3 V...

Page 7: ...s for gaseous fuels Definitions requirements testing marking and EN 267 Forced draught oil burners Definitions requirements testing marking If a burner is to be fitted to an existing boiler maximum combustion efficiency can only be achieved if all heat transfer surfaces are cleaned prior to the installation Generally TD series burners are not suitable for use in areas of high humidity or in explos...

Page 8: ... recommended that the valves have electric switch packs fitted to them so that they can be interlocked with oil operation It is always preferable to use duplex pumping where practical particularly on multi burner installations 1 3 4 Pipe Runs Pipework should be run in a manner that allows it to be self venting and in sections that require venting a suitable vent or de gassing section should be fit...

Page 9: ... inside the front half of the fan cases are the compressor blades on the outside external lugs are attached with pins and thrust bearings to the burner mounting casting to form the hinges The rear half is tapped to take the burner lifting eye and pads are used for the attachment of the components on various models of the burner The rear face is machined to match the air shutter assembly which is a...

Page 10: ...n and noise levels the fans are manufactured and balanced to the very highest standards ISO 1940 2003 All fans are colour coded according to size Combustion Head The air for combustion passes from the burner fan at a pressure related to the resistance of the boiler down the draught tube to the combustion head The latter is an assembly of components which cause the gas to be discharged into the air...

Page 11: ... further reduction of these levels can be made by fitting air inlet silencers which are designed to cover the air shutter castings The standard foam lined silencer typically offers sound levels in the region of 80dBA An optional Snorkel type silencer is available which will reduce sound levels to below 75dBA Silencers can also be tailored to suit ducted air supplies filters or additional acoustic ...

Page 12: ...m3 HR 1 FIRING MODE OPTIONS Fan Motor KW Pump Motor kW Voltage Hz Ph Running Current Starting Current TYPE MIN MAX MIN MAX Mod Gas High Low Oil High Low Electronic Modulation 2 TD410Z 600 4500 58 433 7 5 2 2 380 420 50 3 23 Amp 48 Amp TD415Z 800 5300 77 510 11 0 2 2 380 420 50 3 32 Amp 64 Amp TD420Y 1250 6200 120 596 15 0 2 2 380 420 50 3 39 Amp 88 Amp ...

Page 13: ... external governor for gas pressures up to 350mbar In this configuration the gas valve requires two signals from the burner the air pressure of the burner and furnace resistance of the boiler The furnace resistance is monitored with a stainless steel piece of pipe which is projected into the furnace along the side of the burner head This will require an additional hole or notch in the boiler mount...

Page 14: ...lectronically controlled butterfly valves for the gas regulation The gas valve is generally a Unibloc see component section for details however other valves can also be used depending on site details or customer preference An additional electronically controlled oil metering valve is fitted for oil regulation see principle of operation section for more details TD410 415 Burners with Unibloc Gas Va...

Page 15: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 15 of 165 TD TAD4 Manual Rev 4 TD420 Burners with Unibloc Gas Valve ...

Page 16: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 16 of 165 TD TAD4 Manual Rev 4 1 6 3 TD10 415 Multi Fuel Low Nox Burner General Arrangement ...

Page 17: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 17 of 165 TD TAD4 Manual Rev 4 1 6 4 TD420 Multi Fuel Low Nox Burner General Arrangement ...

Page 18: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 18 of 165 TD TAD4 Manual Rev 4 1 6 5 TAD420 Multi Fuel Low Nox Burner General Arrangement ...

Page 19: ...r and also insulates the burner mounting casting It is important to check that the burner draught tube projection into the combustion chamber conforms to the appliance manufacturers instructions Non standard draught tube projections are available on request please consult the Dunphy sales dept In general for reverse flame boilers the draught tube projection into the combustion chamber should be be...

Page 20: ...n type isolation ball valve next to or in close proximity to the burner and capable of rapid operation The manual valve must be capable of operating at a pressure equal to 1 5 times the maximum supply pressure and where possible must be orientated in such a way that when the valve closes the handle must fall from the vertical to the horizontal The valve must have mechanical end stops to prevent th...

Page 21: ...ng Instructions For TD TAD4 Dual Fuel Burner June 13 21 of 165 TD TAD4 Manual Rev 4 VGD Gas Valve Orientation Unibloc Orientation Governor Orientation Fit governor in accordance with manufactures instructions ...

Page 22: ... on the top flat of the burner hinge section The black line must be connected between the Combustion Chamber connection on the SKP75 and the furnace line connection protruding through the mounting flange of the burner Important The installer must install a 90 turn type isolation ball valve next to or in close proximity to the burner and capable of rapid operation The manual valve must be capable o...

Page 23: ...lustration below PUMP TYPE CONNECTION A CONNECTION B DH1 Series 3 4 BSP 3 4 BSP DH2 Series 1 BSP 1 BSP 2 4 Pump Priming In order to ensure correct start up for DH series oil pumps the following guidelines should be adhered to 1 Ensure that the oil supply to the pump has been properly bled through and that no air is present in the oil supply The flexible oil lines should be fully flooded before con...

Page 24: ...g main gas supply pipework to earth Connections to all terminals and the appliance should be made in accordance with the wiring diagram supplied with each burner The final part of the electrical cable run must be made in flexible conduit long enough to enable the appliance door to be opened Ensure that the mains electrical supply to the burner is protected by a suitably sized fuse Connections to a...

Page 25: ... be available when all access doors fire doors and windows are closed Air supply fans or flue dilution systems must be interlocked to prevent operation of the burner s in the event of fan failure or shutdown To ensure an adequate supply of combustion air the room in which the burner s are installed should have permanent ventilation according to local or national standards ...

Page 26: ... the three M6 locking nuts inside the draught tube and sliding the cone forwards backwards along its adjustment slots until the required setting is obtained Important Notes Factory setting of gas flow is as shown on the following combustion head arrangement drawings Position of gas nozzles must be finalised at commissioning to suit the particular boiler in which the burner is fitted When using low...

Page 27: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 27 of 165 TD TAD4 Manual Rev 4 3 1 High Low Burners ...

Page 28: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 28 of 165 TD TAD4 Manual Rev 4 3 2 Modulating Burners ...

Page 29: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 29 of 165 TD TAD4 Manual Rev 4 3 3 Modulating TD410 Burners Fitted With Low NOx Multi Pipe Gas Head ...

Page 30: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 30 of 165 TD TAD4 Manual Rev 4 ...

Page 31: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 31 of 165 TD TAD4 Manual Rev 4 3 1 Modulating TD415 420 Burners Fitted With Low NOx Multi Pipe Gas Head ...

Page 32: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 32 of 165 TD TAD4 Manual Rev 4 ...

Page 33: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 33 of 165 TD TAD4 Manual Rev 4 3 2 Modulating TD410 Burners Fitted With Low NOx Multi Pipe Gas Head Multi Oil ...

Page 34: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 34 of 165 TD TAD4 Manual Rev 4 ...

Page 35: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 35 of 165 TD TAD4 Manual Rev 4 3 1 Modulating TD415 420 Burners Fitted With Low NOx Multi Pipe Gas Head Multi Oil ...

Page 36: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 36 of 165 TD TAD4 Manual Rev 4 ...

Page 37: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 37 of 165 TD TAD4 Manual Rev 4 3 2 Modulating Burners Fitted With Bio Gas Head ...

Page 38: ...o open or close the nozzle holes 3 3 2 Multipipe Gas Nozzle adjustment The Combustion head is attached to the gas inlet on the body The gas flows through the 6 gas pipes and through the holes in the gas nozzles The gas flow can be altered by rotating the nozzles to direct the gas either towards or away from the centre of the burner The gas nozzles can also be adjusted along the multipipe head this...

Page 39: ...dard 2 stage gas valve When the burner is switched off the air damper will fully close preventing any chimney buoyancy cooling of the appliance Cam IV of the air servo motor is used to set the ignition position of the air damper Once the burner is lit and has stabilised the air damper will move to either the low fire CAM III or high fire CAM I position depending on load demand Travel is adjusted b...

Page 40: ...ted by means of the pump pressure regulating screw to give approximately 50 of the MCR of the appliance and the air shutter adjusted to give optimum combustion efficiency As the control box reaches the high fire stage the air damper motor drives the air shutter to the high fire position and sends a signal to the second stage oil valve V2 As a safety measure the second stage oil valve is energised ...

Page 41: ...66 9 35 22 8 25 0 27 0 30 6 32 3 36 0 5 50 21 0 6 15 6 74 7 28 7 78 8 69 9 53 10 3 25 1 27 5 29 7 33 6 35 4 39 6 6 00 23 0 6 71 7 35 7 94 8 49 9 49 10 4 11 3 27 3 30 0 32 4 36 7 38 7 43 3 6 50 25 0 7 27 7 96 8 60 9 19 10 3 11 3 12 2 29 6 32 5 35 1 39 7 41 9 46 8 7 00 26 5 7 83 8 57 9 26 9 90 11 1 12 1 13 1 31 9 35 0 37 7 42 8 45 1 50 5 7 50 28 0 8 39 9 19 9 92 10 6 11 9 13 0 14 0 34 2 37 4 40 4 45...

Page 42: ...tion and energy saving Its set point is derived from a potentiometer situated and mechanically connected to the back of the air damper motor As the control box drives the air damper motor up and down according to the appliance load characteristics the potentiometer sends a proportional signal to the inverter which makes the fan go faster or slower depending on whether more or less air is required ...

Page 43: ... return of the pump through a safety shut off valve The oil volume is controlled by a metering valve 6 in the spill line restricting the amount of spilled oil and therefore increasing the volume that passes through the nozzle for combustion Control of both the metering valve and the air shutter is achieved by means of independent servo motors which are positioned by the electronic control system K...

Page 44: ...ton limit screw The screw is first fully screwed in so that the piston cannot move the screw is then moved out by 10mm to set the stroke The nozzle has a vent on the back chamber to allow the piston to move DO NOT BLOCK THE VENT 4 3 3 ART 1400 Burner Gun The ART1400 nozzle has a set spring tension and piston stroke no adjustments can be made to the operation of the burner gun The nozzle has a vent...

Page 45: ... 150 195 220 460 3 6 200 44 60 86 126 170 220 245 550 4 225 48 67 96 143 192 250 276 600 4 275 58 80 118 175 240 310 337 700 4 300 62 88 130 195 270 350 368 750 4 330 67 96 145 220 300 395 405 800 4 360 73 106 160 240 335 440 870 4 400 79 117 180 266 375 490 900 4 450 89 133 198 296 420 557 960 4 500 98 148 220 333 467 612 1025 4 550 108 162 248 367 514 673 1100 4 625 124 184 281 417 584 765 1200 ...

Page 46: ... furnace or can return down the spill line to the pump return The control of the oil volume is achieved by a metering valve in the spill line restricting the amount of spilled oil and therefore increasing the volume that passes through the nozzle for combustion Control of both the metering valve and the air shutter is achieved by means of a modulating motor which is positioned by potentiometer acc...

Page 47: ... 2 8 2 75 4 1 11 0 2 7 3 0 4 2 13 0 3 1 3 25 4 75 14 0 2 9 3 5 5 0 15 0 3 0 4 0 5 7 17 0 3 0 4 5 6 5 19 5 3 0 5 0 7 3 22 0 3 0 5 5 7 7 24 0 3 1 6 0 8 5 26 0 3 1 6 5 9 0 28 0 3 1 7 0 9 8 30 0 3 1 7 5 10 2 32 5 3 2 8 0 11 0 35 0 3 2 8 5 11 5 37 0 3 2 9 0 12 2 39 5 3 2 10 0 13 5 44 0 3 3 11 0 15 2 48 0 3 2 12 0 17 0 53 0 3 2 14 0 18 7 62 0 3 3 16 0 21 5 71 0 3 3 18 0 23 8 80 0 3 4 20 0 26 5 88 0 3 3 ...

Page 48: ...two PDV N C solenoid valves open allowing oil to flow through the nozzles The return path from the centre nozzle flows through metering valve MV1 while the three outer nozzle flows through MV2 they then join a common oil line passing through two N C safety shut off valves and back to the return of the pump The oil volume is controlled by the metering valves MV1 and MV2 in the spill line restrictin...

Page 49: ...e pump pressure is set at 25 Bar the two pressure regulators controlling the pressure to all four nozzles are set at 10 Bar On Low fire V1 V2 and V3 are open V4 is closed This allows oil to pass through all four nozzles at a pressure of 10 Bar On High fire V1 V2 V3 and V4 are opened oil at 10 Bar flows through the centre nozzle oil flows through the three outer nozzles at 25 Bar through V4 bypassi...

Page 50: ...tted is energised and the oil temperature is raised to the required level When the oil reaches the required temperature the burner motor pump is started and the oil is allowed to circulate through the burner pipework until the correct temperature is attained throughout the system The check stat then sends a signal to the control box which starts the firing cycle by opening the air damper to the hi...

Page 51: ...te directly coupled fuel pump and drive motor Details of the various sizes of pumps and motors are given in the table below BURNER TYPE PUMP TYPE MOTOR SIZE kW RPM DRIVE COUPLING OIL LINE CONNECTIONS TD410ZHL DH1 1 30 1 1 2800 Fig 71 3 4 BSP TD410ZM DH1 1 30 1 1 or 2 2 2800 Fig 71 3 4 BSP TD415YM DH1 2 30 2 2 2800 Fig 71 3 4 BSP TD420YM DH2 1 30 3 0 2800 Fig 71 1 BSP ...

Page 52: ...on BURNER O I Sets the burner On or Off and enables changes between normal and local operation Note Terminal PE9 must be ON for this switch to start the burner MUTE RESET Press this key to mute open the alarm relays and then hold the key down for approximately three seconds to reset the cleared faults AUTO HAND Selects auto or manual burner modulation In manual mode the UP DOWN keys are used to al...

Page 53: ... controlled by an external circuit 3 Open fuel valve If gas firing and safety valve proving are selected the gas valve servo motor is moved open for five seconds to allow any gas in the test section to be vented easily during the proving sequence 4 Hold fuel valve The fuel motor is held in position until step 1 of the safety valve proving sequence open main valve 2 or vent valve is completed 5 Pro...

Page 54: ...e a flame must be detected or the controller will lockout the burner and move to stage 0 The ignition transformer may optionally be on or off See option parameter 14 6 13 Main ignition Once the pilot interval time t5 has elapsed the second and first if not already open main valve output s for gas or main oil valve output for oil is energized and the second safety time t6 is started If firing on oi...

Page 55: ... the requirement for heat The controller has 2 modes of operation using the standard RATIOTRONIC modulation function Normal and Local The mode of operation is set via the keypad by pushing the Burner ON OFF key and selecting the mode Using the programmable block function option within the controller it is possible for the modulation control to be generated with customised options these are not cov...

Page 56: ...otor fan or pump shaft There is also an option to allow the speed of an additional rotary device to be monitored as an encoder input When not configured to control an inverter the 4 20mA outputs may be configured to transmit system variables as current outputs There are special wiring requirements for inverter feedback 5 8 Post Purge Operation If a post combustion purge is selected with option par...

Page 57: ...t down switch procedure which shuts down the burner in an orderly fashion and turns it off without damaging it an e stop is designed and configured to a completely abort the operation at all costs and b be operable in a manner that is quick simple so that even a panicking user with impaired executive function can operate it and usually c be obvious even to an untrained operator or a bystander The ...

Page 58: ...te input enable 1 3 0 External profile select enable 1 4 0 Gas valve proof of closure select 1 5 0 Oil valve proof of closure 1 6 0 Second airflow switch primary air enable 1 7 0 Safety time configuration set 1 8 0 Force Mode Input 2 0 0 Drive 0 name not used 2 1 2 Drive 1 name gas servo motor 2 2 3 Drive 2 name oil servo motor 2 3 10 Drive 3 name air servo motor 2 4 11 Drive 4 name VSD drive 2 5 ...

Page 59: ... Pre purge time Do not reduce this timing 7 3 1 Pre ignition time Do not extend this timing 7 4 3 Pilot ignition time Do not extend this timing 7 5 3 Pilot hold time Do not extend this timing 7 6 3 Main ignition time Do not extend this timing 7 7 3 Ignition hold time Do not extend this timing 7 8 5 Low fire hold time Do not extend this timing 7 9 30 Post purge time Do not reduce this timing 8 0 0 ...

Page 60: ...3 xx Modulation input span value default temp 150 pressure 16 0 15 4 x Set point display units 1 bar 3 deg c 15 5 0 Boiler high safety limit 15 6 20 Modulation time 15 7 0 Bumpless transfer 15 8 1 Low fire before off 0 no 1 yes 16 1 0 Go back to pilot 16 2 0 Allow profile swap online 16 3 011 HV input 12 alarm lockout function Boiler high limit stat on PE7 16 4 012 HV input 13 alarm lockout functi...

Page 61: ...nable 21 1 x Set point 1 control value default temp 80 pressure 8 0 21 2 0 5 Set point 1 proportional value default temp 1 pressure 0 5 21 3 1 Set point 1 integral time 21 4 0 Set point 1 derivative time 21 5 2 Set point 1 control limit type Deviation 21 6 0 5 Set point 1 low limit control value default temp 10 pressure 0 5 Burner On 0 5 below SP 21 7 0 5 Set point 1 high limit control value defau...

Page 62: ...ensor units 30 5 0 Oxygen input function 30 6 0 Oxygen probe calibrate enable 30 7 0 Boiler transport delay 30 8 0 Reset oxygen trim profile 30 9 0 Automatic trim commissioning 31 0 0 Limit modulation range 31 1 31 4 0 Trim type for profiles 32 0 0 Trim limit default 32 1 32 4 0 Trim limits 33 1 33 4 0 Trim integral gain 34 0 0 Trim proportional gain default 34 1 34 4 0 Trim proportional gain 35 0...

Page 63: ...gain 42 4 0 Maximum oxygen variation 42 5 0 Maximum flue temp variation 42 6 0 Second oxygen probe calibration enable 44 0 0 Set real time clock 44 1 0 Set year 44 2 0 Set month 44 3 0 Set day of month 44 4 0 Set day of week 44 5 0 Set hours 44 6 0 Set minutes 44 7 0 Set seconds 44 9 0 Clear fault history 45 0 0 Erase Restore enable 45 1 0 Erase command 45 2 0 Restore command ...

Page 64: ...TOR TRIP 1 93 THERMISTOR SOURCE NONE ANALOG INPUT 54 3 02 MIN REFERENCE 0 0 HZ 20 0 HZ 3 03 MAX REFERENCE 50 0 HZ 3 13 REFERENCE SITE HAND AUTO REMOTE 3 15 REFERENCE 1 SOURCE ANALOG INPUT 53 3 41 RAMP UP TIME 45 0 SEC 15 SEC 3 42 RAMP DOWN TIME 90 0 SEC 20 SEC PNU NAME FACTORY DEFAULT DCL DEFAULT 4 10 MOTOR SPEED DIRECTION BOTH DIRECTIONS CLOCKWISE 4 12 MOTOR SPEED LOW LIMIT 0 0 HZ 20 0 HZ 4 14 MO...

Page 65: ...L 53 MAX SCALING 20 00 mA 6 14 TERMINAL 53 LOW REF FEEDBACK VALUE 0 00 20 00 6 15 TERMINAL 53 HIGH REF FEEDBACK VALUE 50 00 6 20 TERMINAL 54 MIN SCALING 0 07 V 6 21 TERMINAL 54 MAX SCALING 10 0 V 6 50 TERMINAL 42 ANALOG OUT SPEED 0 HIGH LIMIT SPEED 4 20mA 6 51 TERMINAL 42 MIN SCALING 0 40 6 52 TERMINAL 42 MAX SCALING 100 100 8 30 PROTOCOL FC MODBUS RTU 8 31 ADDRESS 1 2 8 32 BAUD RATE 19200 BAUD 96...

Page 66: ...RESSURE TEMP SCL2 0 0 0 0 SCH2 100 0 100 0 SPL 0 0 0 0 SPH 100 16 0 100 0 PRESSURE TEMP OFF1 0 0 0 0 OFF2 0 0 0 0 OFF3 0 0 0 0 DF1 1 0 1 0 DF3 1278 1278 OLLO 199 9 199 9 OLH1 999 9 999 9 DTT 30 30 AL 0 0 0 0 HYST 1 0 1 0 PB 1 10 0 1 0 10 0 PRESSURE TEMP DT 80 0 25 0 RT 350 100 0 DB 1 0 1 0 TT 15 0 15 0 HYS 1 5 0 1 0 5 0 PRESSURE TEMP HYS 2 3 0 0 5 3 0 PRESSURE TEMP HYS 3 5 0 1 0 5 0 PRESSURE TEMP ...

Page 67: ...n of the appliance but will normally be in the range of 180 to 250 C gross if in doubt what this figure should be please consult the boiler appliance manufacturer Calculation of burner firing rate output Qf Qn k kW Qf Burner Firing Rate Output kW Qn Boiler nominal thermal output kW k Boiler Efficiency Calculation of Gas Throughput at Nominal Boiler Output Vb Qn HU k m h 3 Vb Gas Throughput Fuel In...

Page 68: ...s of the settings for a particular burner firing a given make of boiler cannot be given in a manual of a realistic size however standard basic settings are given in section 3 of this manual The size and relative position of the flame ring to the cone will have an appreciable effect on the volume and velocity of air passing over the flame ring and this must be taken into consideration when setting ...

Page 69: ...he correct size Ensure that a manual gas isolation valve is positioned as close as possible to the burner and that all gas pipe work is adequately supported Check that the external electrical connections are in accordance with the appliance manufacturers wiring instructions Make certain that both fuel supplies and electrical supplies have been isolated Ensure that all gas oil and electrical connec...

Page 70: ... close it again The pressure shown on the manometer should remain constant 7 4 3 Check rotation of burner fan motor Switch on mains electrical supply Momentarily blip the burner fan connector and check rotation of fan against direction of rotation sticker fixed to the rear of the burner If motor rotates in the wrong direction changeover two of the incoming 3 phase supply Repeat test to ensure rota...

Page 71: ... 1 is used to set the Low Fire rate and is used to adjust the high fire rate A combination of the two settings will define an operating line between high fire and low fire and the valve will maintain the air gas ratio across this range Full information on the gas multiblock may be found in section 4 Adjustment of will have an effect on the setting of and vice versa It may take 3 or 4 fine adjustme...

Page 72: ...operation of the selector switch on the burner control cabinet This selector switch controls two contactors which electrically isolate one fuel from the other On electronic modulating burners fuel selection can be made via the keypad For change over to either fuel the switch selection is made through the off position which causes the burner control box to extinguish the flame before recycling The ...

Page 73: ...plate If necessary make adjustments to the combustion head to cure this Check the flame ring for indications of overheating or impingement by the oil spray The basic relative positions of the combustion head components are given in section 3 of this manual but the principles to be followed are that 1 The ignition electrodes must be positioned so that the spark which strikes at the narrowest point ...

Page 74: ...arious component parts is also important When a burner has been in service for a period long enough for its performance to be confirmed and before the settings have been disturbed the relative dimensions of the combustion head components should be recorded so that after dismantling for maintenance correct reassembly can be assured Set the high low thermostat or pressure switch to a lower figure th...

Page 75: ...ointer set to zero this represents maximum flow through the metering valve As the valve modulates up to 90º the valve closes off also closing off the return spill line from the oil nozzle line and therefore increasing the firing rate More details on the oil metering valve can be found in the component section 7 6 3 Adjustment of air pressure proving switch Check the air pressure proving switch and...

Page 76: ... standard test programme This does not mean that the pump pressure or any other adjustment applying to the oil system is necessarily correct for the application Please now refer to Section 6 6 Commission Ratio Mode of the Ratiotronic 6000 manual for details on how to commission the burner 7 6 7 Combustion values and results All combustion readings must be taken with an approved and correctly calib...

Page 77: ...in the various combustion head drawings in this manual are to be regarded as datum figures only During commissioning alterations may be made to the relative positions or to the components themselves to suit the particular application Therefore before dismantling the combustion head take note of the measurements concerned and record them on the manual s drawings It is important that where possible ...

Page 78: ...quantity is found remove the upstream main gas valves from the burner and clean the seats Unibloc only see Unibloc section of this manual for actuator removal The Siemens valve is a sealed unit any unauthorised opening will invalidate warranty b Check and clean any gas filters in the site pipework if significant quantities of dust or scale are found Make a request to the gas region for similar wor...

Page 79: ... diagram section at rear of this manual for relevant positions of the various components a Open the burner as described in the burner maintenance schedule b Disconnect the probe HT lead and where a UV cell is fitted remove this from its retaining clip and move to a safe place c Loosen the jacking screw in the mounting hinge section opposite the gas entry as shown in the illustration below d Pull t...

Page 80: ...move the air damper drive linkage g On the TD3 TD4 and TD5 burners it will be necessary to electrically disconnect the air damper modulation motor h Take out the four fixing bolts and remove the modulation motor mounting bracket i Using suitable lifting gear take the weight of the burner by its lifting eye j Remove the ring of screws which secure the two halves of the fan case k Remove the rear ha...

Page 81: ...TD TAD4 Dual Fuel Burner June 13 81 of 165 TD TAD4 Manual Rev 4 9 Faults and fault finding 9 1 Ratiotronic 6000 6006 Faults relating to electronic modulation burners must refer to the Ratiotronic 6000 controller manual Section 9 ...

Page 82: ...u lb MJ Kg 2 326 x 10 3 ºC ºf Cº x 9 5 32 cm Hg ft of H20 0 4451 cm Hg p s i 0 1928 ft metres 0 3048 gallons US litres 3 785 gallons Imperial litres 4 546 gallons US gallons Imperial 0 83267 Hp kW 0 7457 hp boiler kW 9 803 Inches cm 2 54 Inches of H2O mb 2 54 J Btu 9 48 x 10 4 kg Cal Btu 3 968 kg cm p s i 14 2233 kW Btu hr 3412 kW kg cal min 14 34 Litres gallons Imperial 0 21997 Litres minute gall...

Page 83: ...IONING ENGINEERS NAME FUEL PUMPED RING MAIN GRAVITY SUPPLY NOZZLE TYPE SIZE OIL PUMP WIRING DIAGRAM NO Firing Rate Position Low Fire 1 2 3 4 5 6 7 8 9 High Fire 10 Burner Output CO2 CO O2 NOX Nett Flue Gas Temperature ºC Smoke Number Ambient Temperature Efficiency Electronic Channel 1 Fuel Modulation Channel 2 Air Furnace Pressure Fan Pressure Pump Outlet Pressure bar Oil Return Pressure Spill bar...

Page 84: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 84 of 165 TD TAD4 Manual Rev 4 ...

Page 85: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 85 of 165 TD TAD4 Manual Rev 4 11 Exploded Diagram Spare Parts List 11 1 Modulating Oil Modulating Gas Setup ...

Page 86: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 86 of 165 TD TAD4 Manual Rev 4 ...

Page 87: ...GA21504 10C 1 SNORKEL SILENCER MESH GA16838 11 1 SPACER FOR MOD PLATE GA07961 12 2 ROD END BEARING BEAROS00250 13 1 SERVO MOTOR LINKARM GA18765 14 1 MOD PLATE GA17188 15 1 ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT00745 16 1 T4 CONTROL PANEL MOUNTING BRACKET GA9093 17 1 542 ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA12409 18 1 DOOR FOR 542 ELECTRICAL ENCLO...

Page 88: ...OUPLING 10mm X 3 8 MMC 10 6 L COMPAD00490 52 4 3 8 BSP DOWTY BONDED SEAL SEADOW00100 53 2 PRESSURE SWITCH ADAPTOR BANMAN00170 54 2 1 4 COPPER WASHER COPWAS00075 55 1 SAUTER HIGH OIL PRESSURE SWITCH BAILEY HIGH OIL PRESSURE SWITCH PRESWI00570 PRESWI00700 56 1 BRIDGE HANDLE CONTOL02285 57 2 STANDPIPE ADAPTORS 10mm MSA 10 8 L COMAD00545 58 12 1 2 BSP DOWTY BONDED SEAL SEADOW00110 59 1 1 2 LUCIFER OIL...

Page 89: ...ERGER LAHR SERVO MOTOR SERVBLO00100 78 1 VARIOTRONIC OIL VALVE MOUNTING BRACKET GA16089 79 1 10mm DIAMETER BUNDI TUBE GA23514A 80 1 10mm DIAMETER BUNDI TUBE GA23514B 81 1 10mm DIAMETER BUNDI TUBE GA23514C 82 1 10mm DIAMETER BUNDI TUBE GA23514D 83 10mm DIAMETER BUNDI TUBE BUNDIT00115 84 1 SAUTER LOW OIL PRESSURE SWITCH BAILEY LOW OIL PRESSURE SWITCH PRESWI00400 PRESWI00705 ...

Page 90: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 90 of 165 TD TAD4 Manual Rev 4 11 2 Modulating Oil Modulating Gas with DH2 Pump TD420 Only ...

Page 91: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 91 of 165 TD TAD4 Manual Rev 4 ...

Page 92: ...TRICAL ENCLOSURE GA10724 GA10720 GA12409 18 1 DOOR FOR 542 ELECTRICAL ENCLOSURE DOOR FOR 552 ELECTRICAL ENCLOSURE DOOR FOR 667 ELECTRICAL ENCLOSURE GA10726 GA10722 GA10723 19 1 SIDE ENTRY GASKET GA08990 20 1 GAS TRAIN FLANGE 80 GA07099 21 1 BUTTERFLY VALVE 80mm GA17187 22A 1 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN65 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN80 T4 UNIBLOC SIDE ENTRY ASSEMBLY DN100 GA23518A GA2351...

Page 93: ... GA10125 57 3 MALE STUD COUPLING 12mm x 1 2 MMC 12 8 L COMPAD00425 58 1 SAUTER LOW OIL PRESSURE SWITCH BAILEY LOW OIL PRESSURE SWITCH PRESWI00400 PRESWI00705 59 1 OIL SOL VALVE LUCIFER 1 2 N C 230V SOLOIL00360 60 1 1 2 BSP BANJO BOLT 8 x 72 GA10400 61 1 3 4 BSP BANJO BOLT 9 x 72 GA10401 62 1 MANIFOLD No 6U WITH DH 2 VALVE CLUSTER GA16771 63 1 REDUCING NIPPLE 1 3 4 PIPNIP01450 64 1 COPPER WASHER 1 ...

Page 94: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 94 of 165 TD TAD4 Manual Rev 4 11 3 High Low Oil High Low Gas Setup TD410 Only ...

Page 95: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 95 of 165 TD TAD4 Manual Rev 4 ...

Page 96: ...CHAMFERED CORNERS GA21875 10C 1 SNORKEL SILENCER MESH GA16838 11 4 SPACER FOR MOD PLATE GA07961 12 2 ROD END BEARING BEAROS00250 13 1 SERVO MOTOR LINKARM GA18765 14 1 MOD PLATE GA17188 15 1 ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT00745 16 1 T6 CONTROL PANEL MOUNTING BRACKET GA9093 17 1 542 ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA12409 18 1 DOOR FOR 54...

Page 97: ...m MSA 10 4 L COMPAD00535 43 1 1 4 BSP OIL MANIFOLD BLOCK 4 PORT GA13237 44 1 1 4 MINI BALL VALVE VALOIL00110 45 1 M5 COPPER WASHER COPWAS00025 46 2 0 600 PSI PRESSURE GUAGE PRESGA00100 47 2 MALE STUD COUPLING 10mm x 1 2 MMC 10 8 L COMPAD00495 48 6 1 2 BSP DOWTY BONDED SEAL SEADOW00110 49 1 1 2 LUCIFER OIL SOLENOID VALVE SOLOIL00240 50 2 MALE STUD COUPLING 10mm X 3 8 MMC 10 6 L COMPAD00490 51 2 3 8...

Page 98: ...UMP COUPLING INSERT PUMZCP00665 73 1 1 1kW 2 POLE PUMP MOTOR MOTPUM00120 74 1 MOTOR HANGER BRACKET GA10450 75 4 MOTOR HANGER BRACKET SPACER GA7961 76 1 BRIDGE HANDLE CONTOL02285 77 1 10mm BUNDI TUBE GA23517A 78 1 10mm BUNDI TUBE GA23517B 79 2 10mm BUNDI TUBE GA23517C 80 1 10mm BUNDI TUBE GA23517D 81 1 10mm BUNDI TUBE BUNDIT00115 ...

Page 99: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 99 of 165 TD TAD4 Manual Rev 4 11 3 Modulating Gas High Low Oil Setup TD410 Only ...

Page 100: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 100 of 165 TD TAD4 Manual Rev 4 ...

Page 101: ...RS GA21875 10C 1 SNORKEL SILENCER MESH GA16838 11 4 SPACER FOR MOD PLATE GA07961 12 2 ROD END BEARING BEAROS00250 13 1 SERVO MOTOR LINKARM GA18765 14 1 MOD PLATE GA17188 15 1 ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT00745 16 1 T4 CONTROL PANEL MOUNTING PLATE GA9093 17 1 542 ELECTRICAL ENCLOSURE 552 ELECTRICAL ENCLOSURE 667 ELECTRICAL ENCLOSURE GA10724 GA10720 GA12409 18 1 DOOR FOR 542 ELECTRICAL ENCL...

Page 102: ...IL00110 45 1 M5 COPPER WASHER COPWAS00025 46 2 0 600 PSI PRESSURE GUAGE PRESGA00100 47 2 MALE STUD COUPLING 10mm x 1 2 MMC 10 8 L COMPAD00495 48 6 1 2 BSP DOWTY BONDED SEAL SEADOW00110 49 1 1 2 LUCIFER OIL SOLENOID VALVE SOLOIL00240 50 2 MALE STUD COUPLING 10mm X 3 8 MMC 10 6 L COMPAD00490 51 2 3 8 BSP DOWTY BONDED SEAL SEADOW00100 52 1 POSITIONAL ELBOW 3 4 x 1 2 CONELB00125 53 1 DH1 1 CLOCKWISE R...

Page 103: ...TAD4 Manual Rev 4 74 1 MOTOR HANGER BRACKET GA10450 75 4 MOTOR HANGER BRACKET SPACER GA7961 76 1 BRIDGE HANDLE CONTOL02285 77 1 10mm BUNDI TUBE GA23517A 78 1 10mm BUNDI TUBE GA23517B 79 2 10mm BUNDI TUBE GA23517C 80 1 10mm BUNDI TUBE GA23517D 81 1 10mm BUNDI TUBE BUNDIT00115 ...

Page 104: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 104 of 165 TD TAD4 Manual Rev 4 11 4 Multi Oil Multi Gas Exploded Diagram ...

Page 105: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 105 of 165 TD TAD4 Manual Rev 4 ...

Page 106: ...GA8767 GA8767 22 1 T4 BOILER MOUNTING GASKET GA11741 GA11742 GA11742 23 1 T4 MULTI FLAME MOUNTING SECTION GA20040 GA20134 GA20134 24 1 T415 420 MULTI FLAME MOUNTING SECTION NOSE CONE GA20042 GA20135 GA20135 25 1 T4 AIR GUIDE VANE WHEN FITTED GA22534 GA22534 GA22534 26 3 T4 MULTI FLAME SPLIT BLOCK GA19506B GA19506B GA19506B 27 22 1 8 BSP DOWTY SEAL SEADOW00050 SEADOW00050 SEADOW00050 28 14 1 8 BSP ...

Page 107: ...720 ETCRAT00720 ETCRAT00720 67 1 TWIN VT2 METERING VALVE MOUNTING BRACKET OILMET00753 OILMET00753 OILMET00753 68 16 1 4 BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD00485 COMPAD00485 69 24 1 4 BSP DOWTY SEAL SEADOW00105 SEADOW00105 SEADOW00105 70 5 1 4 BSP x 10mm STANDPIPE ADAPTOR COMPAD00535 COMPAD00535 COMPAD00535 71 3 1 4 BSP MINI OIL BALL VALVE VALOIL00110 VALOIL00110 VALOIL00110 72 3 0 41 ...

Page 108: ...TE PLCSIDENT00120 PLCSIDENT00120 PLCSIDENT00120 96 1 DN80 BUTTERFLY VALVE WITH BERGER LAHR SERVO MOTOR GA17187 GA17187 GA17187 97A 1 T4 DN65 UNIBLOC ASSEMBLY T4 DN80 UNIBLOC ASSEMBLY T4 DN100 UNIBLOC ASSEMBLY GA23518A GA23518B GA23518C GA23518A GA23518B GA23518C GA23518A GA23518B GA23518C 97B 1 T4 DN65 VG4 40 ASSEMBLY T4 DN80 VG4 40 ASSEMBLY T4 DN100 VG4 40 ASSEMBLY GA23529A GA23529B GA23529C GA23...

Page 109: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 109 of 165 TD TAD4 Manual Rev 4 11 5 TD410 Low NOx Combustion Head Assembly 11 6 TD415 420 Low NOx Combustion Head Assembly ...

Page 110: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 110 of 165 TD TAD4 Manual Rev 4 11 7 TD410 Combustion Head Assembly 11 8 TD415 420 Combustion Head Assembly ...

Page 111: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 111 of 165 TD TAD4 Manual Rev 4 11 9 DN65 Unibloc 11 10DN80 Unibloc 11 11DN100 Unibloc ...

Page 112: ...ructions For TD TAD4 Dual Fuel Burner June 13 112 of 165 TD TAD4 Manual Rev 4 11 12VGD40 65 Assembly for Pneumatic Modulating and High Low Burners 11 13VGD40 80 Assembly for Pneumatic Modulating and High Low Burners ...

Page 113: ...g Instructions For TD TAD4 Dual Fuel Burner June 13 113 of 165 TD TAD4 Manual Rev 4 11 14VGD40 100 Assembly for Pneumatic Modulating and High Low Burners 11 15VGD40 65 Assembly for Electronic Modulating Burners ...

Page 114: ...erating Instructions For TD TAD4 Dual Fuel Burner June 13 114 of 165 TD TAD4 Manual Rev 4 11 16VGD40 80 Assembly for Electronic Modulating Burners 11 17VGD40 100 Assembly for Electronic Modulating Burners ...

Page 115: ...produce erroneous flame signals Mounting notes Ensure that the relevant national safety regulations are observed When using 2 UV detectors QRA make certain that the detectors cannot see one another Installation notes Installation work must be carried out by qualified staff Always run the high voltage ignition cables separately while observing the greatest possible distance to the unit and to other...

Page 116: ...ely multicore cable not allowed max 80 m Shielded cable max 140 m e g high frequency cable shield connected to terminal 22 Flame supervision with QRA Supply voltage Operation AC 330 V 10 Test AC 380 V 10 Required detector current min 70 µA Possible detector current Operation max 680 µA Test max 1000 µA Perm length of detector cable Normal cable laid separately Multicore cable not permitted max 100...

Page 117: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 117 of 165 TD TAD4 Manual Rev 4 LFL Technical Data ...

Page 118: ...10 A slow Power consumption approx AC 3 5 VA Perm input current at terminal 1 max 5 A continuously peaks up to 20 A for 20 ms Perm load on control terminals 3 6 7 9 11 15 20 max 4 A continuously peaks up to 20 A for max 20 ms total max 5 A Required switching capacity of switching devices 1 A AC 250 V Between terminals 4 and 5 1 A AC 250 V Between terminals 4 and 12 min 1 A AC 250 V Between termina...

Page 119: ...C contact of the air pressure switch must be closed LP test Start up sequence A Start command delivered by R for instance A B Startup sequence B Operating position of the burner B C Burner operation according to the control commands delivered by R C Controlled shutdown via R C D Sequence switch travels to start position A postpurging During burner off periods only control outputs 11 and 12 carry v...

Page 120: ...equent burner operation t5 Interval On completion of t5 power is fed to terminal 20 at the same time control outputs 9 11 and input 8 are galvanically separated from the unit s control section The LFL1 is now protected against return voltages from the power control loop The startup sequence of the LFL1 ends with the release of LR at terminal 20 After a number of idle steps steps with no change of ...

Page 121: ...t Do not press the lockout reset button for more than 10 seconds The sequence switch always returns to its start position first After resetting After correction of a fault which resulted in plant shutdown After each power failure During that period of time power is only fed to terminals 7 and 9 11 Then the LFL1 begins with a new burner startup sequence ...

Page 122: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 122 of 165 TD TAD4 Manual Rev 4 LFL Glossary of symbols ...

Page 123: ...mperature It is configured to modulate the burner up and down when firing on gas and provide high low thermostat functions when firing on oil In modulating operation the RWF40 operates as a PID controller In 2 stage operation the RWF40 provides control based on the set switching threshold The setpoint of the RWF40 can be adjusted either on the controller itself or externally ...

Page 124: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 124 of 165 TD TAD4 Manual Rev 4 ...

Page 125: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 125 of 165 TD TAD4 Manual Rev 4 ...

Page 126: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 126 of 165 TD TAD4 Manual Rev 4 ...

Page 127: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 127 of 165 TD TAD4 Manual Rev 4 ...

Page 128: ...the various gas valve actuators that are described in section 2 The standard unit is designed for use with 2nd and 3rd family gases and is fitted with plated carbon steel valve seating rings For other gas applications e g bio or producer gas the valve seating rings are manufactured out of grade 321 stainless steel because of the corrosive nature of these gases Where hydrogen sulphide H2 S is prese...

Page 129: ...ill be within the range of 0 C to 50 C ensure that the gas supply pipework is clean and contains no loose particles fit valve to pipework so that the gas flow travels in the direction of the arrows on the valve casing Please note that the 40 50 65 80 and 100 mm N B valve bodies should be mounted with the inlet flange facing vertically downwards The 125 mm N B valve body has an adjustable inlet fla...

Page 130: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 130 of 165 TD TAD4 Manual Rev 4 12 3 2 65mm Ratiotronic Unibloc exploded diagram and parts list ...

Page 131: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 131 of 165 TD TAD4 Manual Rev 4 12 3 3 65mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ...

Page 132: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 132 of 165 TD TAD4 Manual Rev 4 ...

Page 133: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 133 of 165 TD TAD4 Manual Rev 4 12 3 4 80mm Ratiotronic Unibloc exploded diagrams and parts list ...

Page 134: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 134 of 165 TD TAD4 Manual Rev 4 12 3 5 80mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ...

Page 135: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 135 of 165 TD TAD4 Manual Rev 4 ...

Page 136: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 136 of 165 TD TAD4 Manual Rev 4 12 3 6 100mm Ratiotronic Unibloc exploded diagrams and parts list ...

Page 137: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 137 of 165 TD TAD4 Manual Rev 4 12 3 7 100mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ...

Page 138: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 138 of 165 TD TAD4 Manual Rev 4 ...

Page 139: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 139 of 165 TD TAD4 Manual Rev 4 12 4 Butterfly Gas Valve 12 4 1 General Arrangement ...

Page 140: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 140 of 165 TD TAD4 Manual Rev 4 12 4 2 Exploded Diagram ...

Page 141: ...y regulations are complied with To mount the double gas valve VGD20 2 flanges type AGA41 AGA51 are required To prevent cuttings from falling inside the valve first mount the flanges to the piping and then clean the associated parts On the gas train the valve can be mounted in any position but the permissible mounting positions of the associated actuator must be observed refer to the relevant Data ...

Page 142: ...tects the valve and downstream controls against dirt Valve body and connecting flanges are made of die cast aluminium the seals of nitril rubber and the stems of stainless steel The double gas valves feature a pilot gas connection Rp Gas valve flanges and actuators are supplied as separate items The 4 screws required to fit the SKP to the valve are contained in the terminal compartment No special ...

Page 143: ...ce increases as the inlet pressure increases class A valve to EN 161 A strainer on the inlet side protects the valve and downstream controls against dirt The 4 screws required to fit the SKP to the valve are contained in the terminal compartment The double gas valves DN40 150 correspond to the standard valve sizes of single valves EN 558 The VGD40 are supplied with a pilot gas flange having a conn...

Page 144: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 144 of 165 TD TAD4 Manual Rev 4 Power Output Curves ...

Page 145: ...ng Its field of use are primarily forced draft gas burners with mechanical fuel air ratio control with electronic fuel air ratio control The SKP55 operates as a differential pressure governor Its field of use are primarily combustion plant with combined heat recovery systems plant where pressure conditions in the burner and in the combustion chamber do not change in proportion to load changes burn...

Page 146: ...SKP it must be lowered by an upstream pressure controller The pressure switch for lack of gas must always be fitted upstream of the gas valve when used in connection with the SKP The inside diameter of the impulse pipes must be a minimum of 6 mm The impulse pipes must be installed such that the differential pressure can be acquired with no disturbance unfavourable flow conditions Pressure test poi...

Page 147: ... flue gas damper the combustion chamber pressure must be fed to the SKP75 as a disturbance variable enabling the controller to counteract Ensure that the relevant national safety regulations are complied with The quadratic arrangement of the fixing holes allows the actuator to be fitted in 4 different positions each step being 90 The actuator can be mounted or replaced while the system is under pr...

Page 148: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 148 of 165 TD TAD4 Manual Rev 4 ...

Page 149: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 149 of 165 TD TAD4 Manual Rev 4 ...

Page 150: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 150 of 165 TD TAD4 Manual Rev 4 ...

Page 151: ...ection possible by plug connection series 01 02 03 No rewiring is required for contact allocation as per DIN 4791 Series 04 and series 05 electrical connection at screw terminals via PG 13 5 cable entry Suitable for gases of gas families 1 2 3 and other neutral gaseous media Not suitable for use with hydrogen VDK 200 H2 to be used for hydrogen Approvals EC type test approval as per EC Gas Applianc...

Page 152: ...n VPS 504 Series 01 02 03 IP 40 VPS 504 Series 04 05 IP 54 Ambient temperature 50 Hz 230 VAC 15 C to 70 C others 15 C to 60 C Release time Approx 10 26 s depending on test volume and input pressure Sensitivity limit max 50 l h At inlet pressures of 50 mbar limit pressure rates well below 50 l of air per hour occur due to the mode of operation This allows for applications involving low inlet pressu...

Page 153: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 153 of 165 TD TAD4 Manual Rev 4 Electrical Connections ...

Page 154: ...European standard for the 4Nm required torque for operating this type of valve 12 7 3 Valve Maintenance All rotating valves do eventually require maintenance but maintenance is only generally necessary as a result of wear on oil seals or O rings as a general guide we recommend that O rings are normally re placed every 2 years or 20 000 hours but this could vary on the type of fuel being used gener...

Page 155: ...1 over the valve spindle angular movement It is possible to adjust the output of the valve whilst still maintaining the large amount of linearization by adjusting the spool ring on the inner scale plate This is adjusted by loosening the retaining cap and rotating the spool with a peg spanner The index mark on the spool indicates the spool position which can be read in conjunction with the flow cha...

Page 156: ...Operating Instructions For TD TAD4 Dual Fuel Burner June 13 156 of 165 TD TAD4 Manual Rev 4 12 7 8 Exploded Diagram ...

Page 157: ...a of the gears As a result the design has catered for bearings of large surface area This must result in minimal rubbing speed They must also provide rigid shaft support with no appreciable deflection The final design provides all DH series with gear sets of nitrogen hardened steel supported by an extremely strong bearing assembly It enables the standard unit to handle fuels with viscosities from ...

Page 158: ... in contact with the cylinder bore by the pressure of oil acting on its annular area This combination of material selection and fine tolerance eliminates edge filtration prevents sticking in operation and reduces hysteresis effects to an absolute minimum The Dunphy DH Series of oil pumps has been purposefully designed in house to a demanding brief by experienced engineers who have learned at plant...

Page 159: ... CAPACITY A number of variants can be offered There are two basic gear sets available in the range these cover swept volumes from 290 to 4500 litres hour at 2 pole 2850 rpm and 3400 rpm speed The further variants arise from the potential of using the pumps as SINGLE SERIES or TANDEM sets as described in the diagrams below SINGLE gear set The SERIES arrangement provides a similar CAPACITY to the SI...

Page 160: ...to the pump inlet port at a pressure between 1 and 2 bar 12 8 3 2 Filtration Filters must be fitted in the oil supply system to prevent foreign matter entering the pumps and possibly affecting performance or causing physical damage All DH1 fuel are supplied with internal filters however when pumps are used with residual fuel oils it is recommended that this filter is removed after approximately on...

Page 161: ... not opening Blocked atomising nozzle Fuel starvation Pump noisy Gas or air in pump Pump worn Blocked line filters Insufficient pressure in pumped ring main to suppress gas formation in the suction side of the pump Fluctuating Oil Pressures Dirt in regulating valve High vacuum at pump suction Fuel starvation Worn pump Pump drive slipping Air leakage into the system Low Oil Pressures Pump undersize...

Page 162: ...LUG OR SUCTION RETURN OIL INLET B S P P OIL INLET B S P P ALTERNATIVE OIL INLET ALTERNATIVE OIL INLET OIL FLOW DIAGRAM FOR TYPE DH1 FUEL PUMPS ROTATION ROTATION OIL RETURN OIL UNDER PRESSURE OIL UNDER SUCTION PLUG OR VACUUM GAUGE PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PRESSURE REGULATOR OIL OUTLET TO NOZZLE RETURN FROM BURNER SHOWN OUT OF POSITION FOR CLARITY RETURN FRO...

Page 163: ...N RETURN OIL INLET B S P P OIL INLET B S P P ALTERNATIVE OIL INLET ALTERNATIVE OIL INLET OIL FLOW DIAGRAM FOR TYPE DH2 FUEL PUMPS ROTATION ROTATION PLAN VIEW PLAN VIEW OIL RETURN OIL UNDER PRESSURE OIL UNDER SUCTION PLUG OR VACUUM GAUGE PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PRESSURE REGULATOR OIL OUTLET TO NOZZLE RETURN FROM BURNER SHOWN OUT OF POSITION FOR CLARITY RET...

Page 164: ...2 1 DH2 2 DH2 2 TYPICAL POWER CONSUMPTION 1425 RPM kW 8 7 6 5 4 3 2 1 0 0 5 10 15 20 25 30 35 40 bar DHO 1 DH1 1 DH1 2 DH2 1 DH2 1 DH2 2 DH2 2 TYPICAL POWER CONSUMPTION 2850 RPM bar 2500 2000 1500 1000 500 0 0 40 30 20 10 litres Hr DHO 1 DH1 1 DH1 2 DH2 1 DH2 2 NOZZLE CAPACITY SINGLE AND TWO STAGE PUMPS 1425 RPM 1000 bar DH1 2 5000 litres Hr 4000 3000 2000 0 0 10 20 30 40 DH2 2 NOZZLE CAPACITY TWO...

Page 165: ...Instructions For TD TAD4 Dual Fuel Burner June 13 165 of 165 TD TAD4 Manual Rev 4 DUNPHY COMBUSTION LTD QUEENSWAY ROCHDALE ENGLAND OL11 2SL Tel 44 0 1706 649217 Fax 44 0 1706 655512 Internet http www dunphy co uk ...

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