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57

Automatic Furnace Controller LFL 1... / LGK 16...

The LGK 16… type controller is desi-
gned to control and monitor burners
working according to a stepwise or
modulating principle. A detailed functio-
nal description with technical data and
project planning information with
respect to the automatic combustion
controllers can be found in the annex
and in the documents

LFL 1...-7451 D
LGK 16...-7785 D

Functional diagram
LFL 1... / LGK 16...

A =

Starting type interval

A-B= Flame development interval
B =

Burner has reached operating
position

B-C= Burner operation

(heat generation)

C-D= regular shut-off
t1

Pre-ventilating time

t2

Safety time

t3

Pre-ignition time

t4

Fuel valve enable

t5

Load regulator enable

t11

„OPEN“ run time of air damper

t12

„CLOSE“ run time of air damper

R =

Temperature or pressure
controller

G =

Fan motor

Z =

Ignition transformer

BV=

Fuel valve(s)

LR=

Load regulator

LK=

Air damper

RV=

Steadily adjustable fuel valve

FS=

Signal of flame

ZBV= Ignition burner valve

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Summary of Contents for RPD 100

Page 1: ...Operation Manual For the authorized specialist Dual fuel Duoblock Burner RPD 30 100 GL R GS R 03 2005 102 877 8447...

Page 2: ...le Assembly DG 75 54 Oil Pressure Switch Air Pressure Switch 55 Setting Pressure Switches and Control System 56 Automatic Furnace Controller LFL 1 LGK 16 57 Flame Monitor Sensor Current Measurement 58...

Page 3: ...uld be started initially by the installer manufacturer or other specialized personnel Prior to taking the furnace system into opera tion make a test of all automatic con trol safety and control facili...

Page 4: ...range 954 6042 kW RPD 30 81 513 kg h 95 604 m h fully modulating Light oil heavy oil natural gas special fuels LFL 1 LGK 16 or other approved models QRA 2 QRA 53 or other approved models MAT Hegwein Z...

Page 5: ...inder Monitoring system Flame monitoring by means of flame sensor and tested burner control box Combustion air monitoring achieved through differential air pressure switch resp speed control switch in...

Page 6: ...Output range 2232 14511 kW RPD 60 188 1223 kg h 223 1451 m h fully modulating Light oil heavy oil natural gas special fuels LFL 1 LGK 16 or other approved models QRA 2 QRA 53 or other approved models...

Page 7: ...high turn down ratios Electric design Burner pre wired and ready to con nect All burner components wired to the burner terminal rail Burner control box supplied loose for installation in separate con...

Page 8: ...ssure loss in mixing unit Gas control organ Burner output Output range 7000 42000 kW RPD 90 590 3540 kg h 700 4200 m h fully modulating Light oil heavy oil natural gas special fuels LFL 1 LGK 16 or ot...

Page 9: ...oller with adjustable cam discs for pri mary air air dampers and secondary air air cylinder Monitoring system Flame monitoring by means of flame sensor and tested burner control box Combustion air mon...

Page 10: ...e 21 Burner tube 23 Secondary air control valve 24 Extracting assembly 26 Burner housing 27 Ignition burner 28 Nozzle rod 29 Oil pressure switch 30 Oil flow rate controller 32 Electric actuator Combus...

Page 11: ...exhaust gas connection if any Boiler lining The boiler lining must consist of heat resistant materials temperature resi stance 1400 C Take care that the burner flame tube is covered by the boiler lin...

Page 12: ...ve The fan impeller is mounted on its own shaft by means of a bearing specifically designed for the purpose The power is transmitted from the drive motor via V belts which can provide practically any...

Page 13: ...ensioned Drawing for RPD Burner 20 100 Oil Gas and Dual fuel Burners without external exhaust gas return Boilerplate holes Set screw M Lenght K Attention for burners type U Mixing unit see on separate...

Page 14: ...26 520 565 18 469 780 580 1360 900 30 740 170 1995 80 1350 75 19 315 375 75 765 860 1450 1400 740 710 597 646 18 600 820 675 1495 1000 30 700 185 2285 90 1700 75 3 420 375 75 870 890 1800 1750 883 870...

Page 15: ...afety shutt off valve 147 Test burner w push button valve 148 Safety blow off valve 150 Gas butterfly valve 151 Ignition burner lance 152 Air regulating valve 153 Main gas solenoid valve 154 Safety sh...

Page 16: ...4 Pressure governor 145 Safety shutt off valve 147 Test burner w push button valve 148 Safety blow off valve 150 Gas butterfly valve 151 Ignition burner lance 152 Air regulating valve 153 Main gas sol...

Page 17: ...stand by Zirkulation Oil circuit at burner pre purge Oil circuit at burner operation 1 Oil pressure pump 2 Safety valve 3 Oil filter 4 Pressure gauge feed line 5 Oil regulating valve 6 Manual valve fo...

Page 18: ...Zirkulation Oil circuit at burner operation 1 Oil pressure pump 2 Safety valve 3 Oil filter 4 Pressure gauge feed line 5 Oil regulating valve 6 Manual valve for bleeding 7 Circulating valve 9 Hydrauli...

Page 19: ...t 12 washer 13 surclip 14 spring 15 washer 16 surclip 17 regulating needle 18 spring 19 washer 20 shaft 21 gasket 22 bush gland 29 shaft 30 piston 31 gasket 32 lock washer 33 nut M8 34 spring 35 sprin...

Page 20: ...pansion and absorb vibrations Ignition gas connection An ignition burner is used to ignite the main gas flame The ignition gas line is branched out of the gas control group between the two gas valves...

Page 21: ...odes are adjusted in accordance with the dra wing When installing new electrodes these must be bent cut to length and adjusted as required The internal resistance of the ionization system amounts to s...

Page 22: ...em Qty Description Part No Material 1 1 Transformer unit Z 112 K 5 Housing of GAL 2 1 Right angle plug with 2 unions A 5 Z 1 10 pole max 2 5 3 1 Gas test socket Z 138 Z 2 Ms 58 4 4 Hexagon socket head...

Page 23: ...ont view Side view 110 mm for natural gas 90 mm for propane Top view Natural gas Propane Electrodes Z 707 F 3 Ceramic Z 545 F 11 Ring W 715F 101 Bush Z 789F 10 Preset amount of bend and adjustment Cut...

Page 24: ...nstallation When installing the valve in the pipeline take care to observe the arrow on the valve housing and the required moun ting position For screwing the pipeline into the valve housing do not us...

Page 25: ...burner and the storage tank a ring line system with gas air separater will be needed for supplying the burners NOTE In case of pressurized oil feed the suction pressure of the pump should not exceed 5...

Page 26: ...stead of the electric tracing lines To avoid burner trouble due to entrained air a gas air vent must be provided at the uppermost position of the ring pipe system The ring pipe pressure must be contro...

Page 27: ...d protect the motor by means of a motor protection switch 3 Commissioning 3 1 The pump must not be allowed to run dry Before initial commissioning of the pump fill the pump with operating medium and o...

Page 28: ...erating housing Al Si alloy Cover plate Al Si alloy Guarantees the best emergency running characteristics and long service life Flow rate Approx 3 420 l min Operating pressure Max 40 bar Supply pressu...

Page 29: ...ontrol boxes related to the bur ner must also be connected in accordance with the enclosed circuit diagram and VDE 0116 and taking into account the local regulations After the electrical connections h...

Page 30: ...Item 13 to the return pipe This causes the oil to be forced to the nozzle with part of the oil flowing back through the return opening of the nozzle Item 11 and the nozzle rod The return oil flow rate...

Page 31: ...be returned through the return flow pipe 6 via the return flow hole of the nozzle The return flow rate is controlled according to the required output using an output pressure control valve Approved sh...

Page 32: ...32 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 27 Article No 145 513 5899 Oil kg h m 2 alpha p return bar Test conditions...

Page 33: ...33 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 27 Article No 145 513 5902 Oil kg h m 2 alpha p return bar Test conditions...

Page 34: ...34 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 27 Article No 145 513 5913 Oil kg h m 2 alpha p return bar Test conditions...

Page 35: ...35 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 27 Article No 145 513 5924 Oil kg h m 2 alpha p return bar Test conditions...

Page 36: ...36 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 50 Article No 145 513 5946 Oil kg h m 2 alpha p return bar Test conditions...

Page 37: ...37 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 50 Article No 145 513 5957 145 513 5968 Oil kg h m 2 alpha p return bar Test conditions...

Page 38: ...38 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 50 Article No 145 513 5979 Oil kg h m 2 alpha p return bar Test conditions...

Page 39: ...39 Throughput Rate Charakteristics Light Fuel Oil Return Nozzle MK 50 Article No 145 513 6007 145 513 5991 Oil kg h m 2 alpha p return bar Test conditions...

Page 40: ...40 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 27 Article No 145 513 5899 Oil kg h m 2 alpha p return bar Test conditions...

Page 41: ...41 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 27 Article No 145 513 5902 Oil kg h m 2 alpha p return bar Test conditions...

Page 42: ...42 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 27 Article No 145 513 5913 Oil kg h m 2 alpha p return bar Test conditions...

Page 43: ...43 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 27 Article No 145 513 5924 Oil kg h m 2 alpha p return bar Test conditions...

Page 44: ...44 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 50 Article No 145 513 5946 Oil kg h m 2 alpha p return bar Test conditions...

Page 45: ...45 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 50 Article No 145 513 5957 145 513 5968 Oil kg h m 2 alpha p return bar Test conditions...

Page 46: ...46 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 50 Article No 145 513 5980 Oil kg h m 2 alpha p return bar Test conditions...

Page 47: ...47 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 50 Article No 145 513 5979 Oil kg h m 2 alpha p return bar Test conditions...

Page 48: ...48 Throughput Rate Charakteristics Heavy Fuel Oil Return Nozzle MK 50 Article No 145 513 5991 145 513 6007 Oil kg h m 2 alpha p return bar Test conditions...

Page 49: ...49 Dimensions of the Mixing Unit standard versions RPD 30 RPD 80...

Page 50: ...can be removed see burner hinge arrangement In case of component replacements or service work on the components of the burner head the correct position of the burner head components have to checked a...

Page 51: ...ter loose ning of the lock screws of the socket headed studs and sliding ball the con trol curve is adjusted over the whole control range by means of the cam disk after which setting is then locked wi...

Page 52: ...tor with disconnecting unit for manual operation 15 Hand wheel for manual adjust ment of mechanical compound controller 16 Return flow connection only heavy oil 17 Feed line hose connector 18 Solenoid...

Page 53: ...by a spring 2 As the pres sure on the side of the valve needle rises above the spring pressure the piston will be lifted and the oil caused to flow over to the pressureless side For the installation...

Page 54: ...not be re used Replacement 1 In place of the end nut 4 use location tool 5 2 Remove plug in sleeve 6 fitted for protection of sleeve only and move sleeve over threads and valve needle 3 Using a piece...

Page 55: ...essive media DSF 158 F 0 25 bar 1 5 8 0 bar Optional return line acc to EN 267 aggressive media alternative if finer switch difference required DSF 152 F 0 16 bar 1 2 3 5 bar Return line acc to EN 267...

Page 56: ...universal controller type RWF 32 can also be used with infinitely variable con trollable burners This controller is spe cially designed for furnace temperature and pressure control of burners using co...

Page 57: ...D LGK 16 7785 D Functional diagram LFL 1 LGK 16 A Starting type interval A B Flame development interval B Burner has reached operating position B C Burner operation heat generation C D regular shut of...

Page 58: ...See data on unit KF 8832 for sensor current measurement UV current measurement with QRA 5 For an accurate UV current measure ment it is recommended to make use of the tester KF 8832 If a normal meter...

Page 59: ...Data Voltage 230 V 10 Protection class IP 54 DIN 400 50 Frequency 50 Hz 60 Hz Installationposition no restriction Operating time 25 30 sec at 90 Torque N 4 40 Nm N 4A 60 Nm N 5 110 Nm Weight N 4 3 4...

Page 60: ...321 H types switch on operation approx 300 ms switch off operation approx 50 ms 121 G types switch on operation approx 50 ms switch off operation approx 20 ms Media Fuel oil EL L M S DIN 51603 please...

Page 61: ...cation safety shut off valve as rapid action device for use in return pipes of atomizing oil burners accor ding to DIN 4787 and TRD 411 With regard to current standards this valve must be connected in...

Page 62: ...C direct current magnet direct current magnet with integrated rectifier above 100 C and in T V version with seperate rectifier Protection IP 65 Energized duty rating ED 100 Connection Pg9 Pg11 applian...

Page 63: ...t 4 magnet unit 5 armature control tube 6 gland 7 gland 8 retaining ring 9 locking ring 10 return spring 11 spring housing 12 locking Ring 13 hex head bolt 14 hex nut 15 lock washer 16 seal dynamic 17...

Page 64: ...direct current magnet direct current magnet with integrated rectifier above 100 C and in T V version with seperate rectifier Protection IP 65 Energized duty rating ED 100 Connection Pg9 Pg11 applianc...

Page 65: ...sive and shearing loads are brought to bear on the valve because this could lead to functional trouble The direction of flow indicated on the 2 2 way valves by arrows should in any case be adhered to...

Page 66: ...Class 1 6 Scale range Order no 0 6 bar 0 10 bar 0 16 bar 0 25 bar 3333 261 128 0 40 bar 109 016 0374 0 60 bar 109 811 4290 0 100 bar 109 811 4303 Bimetal Pointer Temperature controller TBW 31 H Measu...

Page 67: ...nded sleeve opening For codes f and connection modes B C D E ES Q and V the sensor is locked by the manufacturer by means of the terminal attached to the capillary line Electrical connection 1 Opening...

Page 68: ...rate and the available gas pressure and installed to the burner on the shortest possible way with minimum pressure loss To provide the most effective conditions for start up take care that the burner...

Page 69: ...s been rea ched As the pressure decreases the pump will be shortly run again For clo sing the valve shut off the voltage which will cause the oil pressure to return to zero and the closing spring forc...

Page 70: ...ly ope ning For electrical connection see figure cen tre left The following versions are available with volumetric flow control valve standard The 1st stage can be adjusted with a switch between 0 and...

Page 71: ...eparate safety blow off valve Blow off line R 1 Safety blow off valve Instrument line 12 mm appr 10 x d Gas pressure regulator with built in safety blow off valve Vent line 1 2 Instrument line appr 10...

Page 72: ...cessary to slightly readjust the pressure turning the setpoint set ting screw clockwise or counterclock wise will increase or decrease the pressure respectively With the setpoint setting not known or...

Page 73: ...operation Open the gas shut off valve very slowly Watch the outlet pressure on the pres sure gauge and readjust the load spring if required Take care for adjustment that the gas is not flowing because...

Page 74: ...ridge is not at hand it will be possible to wash the filter mat in 40 C water adding some light duty detergent Allow the mat to dry before reinstallation NOTE For the installation of the filter mat ta...

Page 75: ...e p value read as a function of the volumetric flow rate by the specific gravity of the gas Reading example damper dia 50 mm V 150 m h natural gas p reading 6 mbar specific gravity of natural gas 0 81...

Page 76: ...40 50 60 70 80 90 100 110 120 0 1 2 3 4 5 6 7 8 9 10 QF MW W m s 18 22 26 RPD 30 u 40 8 nozzles 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 0 2 4 6 8 10 12 14 16 18 20 22 QF MW W m s 018 022...

Page 77: ...Gas Nozzles 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 QF MW W m s 8 31 8 35 6 RPD 80 16 nozzles 0 10 20 30 40 50 60 70 80 90 100 0 5 10 15 20 25 30 35 40 45 50 QF MW W m s 0 31 0 35 6...

Page 78: ...gh a vent line and make a check with a test burner in the outlet area of the burner Functional test without fuel Check the burner for proper functional order without using a fuel In gas opera ting mod...

Page 79: ...on For checking the direction of rotation of the air fan and pump motors direct connection shortly actuate or press the contactor In star delta connection layouts it will be necessary to actuate the m...

Page 80: ...st be mounted ready for operation Ensure that the heating system is filled with water Check the complete system for correct electrical wiring Check the air fan and pump motor for correct direction of...

Page 81: ...St Max feeding viscosity M axim um viscosity of heavy fuel oil acc to DIN 51 603 Failure of heavy fuel oil Temperature C max Atomizing viscosity heavy fuel oil M axim um viscosity of fuel oil grade EL...

Page 82: ...switch to its position 0 and allow the after ventilation period to run down 2 Set the selector switch to the desi red fuel type Measures in case of trouble Any trouble of the burner will be indica ted...

Page 83: ...g 22 1011 Cologne 45 1009 Leipzig 130 998 Magdeburg 79 1005 Munich 526 955 Nuremberg 310 980 Rostock 4 1013 Stuttgart 297 984 Schwerin 59 1010 Ulm 479 960 Volumetric gas flow rate at STP Volumetric ga...

Page 84: ...ntent in exhaust gas from heavy oil combustion SO2 in dry exhaust gas Sulphur content in fuel by wt C O 2 c o n t e n t i n e x h a u s t g a s 1 5 b y v o l CO2 by vol CO2 by vol Sulphur content in f...

Page 85: ...29 4 80 9 10 1 30 4 90 9 05 1 30 5 00 8 99 1 31 5 10 8 93 1 32 5 20 8 88 1 33 5 30 8 82 1 34 5 40 8 77 1 35 5 50 8 71 1 35 5 60 8 65 1 36 5 70 8 60 1 37 5 80 8 54 1 38 5 90 8 48 1 39 6 00 8 43 1 40 6...

Page 86: ...1 29 4 80 10 65 1 30 4 90 10 58 1 30 5 00 10 51 1 31 5 10 10 45 1 32 5 20 10 38 1 33 5 30 10 32 1 34 5 40 10 25 1 35 5 50 10 19 1 35 5 60 10 12 1 36 5 70 10 05 1 37 5 80 9 99 1 38 5 90 9 92 1 39 6 00...

Page 87: ...4 80 11 88 1 30 4 90 11 81 1 30 5 00 11 73 1 31 5 10 11 66 1 32 5 20 11 59 1 33 5 30 11 51 1 34 5 40 11 44 1 35 5 50 11 37 1 35 5 60 11 29 1 36 5 70 11 22 1 37 5 80 11 15 1 38 5 90 11 07 1 39 6 00 11...

Page 88: ...80 12 27 1 30 4 90 12 19 1 30 5 00 12 11 1 31 5 10 12 04 1 32 5 20 11 96 1 33 5 30 11 89 1 34 5 40 11 81 1 35 5 50 11 74 1 35 5 60 11 66 1 36 5 70 11 58 1 37 5 80 11 51 1 38 5 90 11 43 1 39 6 00 11 36...

Page 89: ...gnition elec trode short cir cuit Adjust electrodes Wide ignition electrode spacing Adjust electrodes Dirty and wet electrodes Clean electrodes Cracked insulator Replace insulator Defective igni tion...

Page 90: ...to start Check connection of automatic fur nace controller Trouble lamp lights flame trouble Unlock and search for cause UV Radiation too weak Check combus tion setting Burner starts without flame for...

Page 91: ...vice ELCO GmbH D 64546 M rfelden Walldorf ELCO Austria GmbH A 2544 Leobersdorf ELCOTHERM AG CH 7324 Vilters ELCO Rendamax B V NL 1410 AB Naarden ELCO Belgium n v s a B 1731 Zellik ELCO Italia S p A I...

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