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Mechanical Compound Controller

Fuel-air compound controller
mounting bracket

Secondary air damper control lin-
kage

Primary air control arm

Primary air control linkage

Primary air angular control arm

Spring-loaded sliding block for
gas control

Hexagon socket head screw with
pressed-in sliding ball (locked by
means of hexagon socket head
screws on end face of cam wheel)

Spring-loaded sliding block for
secondary combustion air

Cam disk on drive shaft

Drive shaft

Spring-loaded sliding block for pri-
mary air

Spring-loaded sliding block for oil
flow rate control

Transmission rod for gas flow rate
control damper

Actuator with disconnecting unit
for manual operation

Hand wheel for manual adjust-
ment of mechanical compound
controller

Return flow connection (only
heavy oil)

Feed line hose connector

Solenoid stop valve

Pressure gauge stop valve

Oil pump pressure gauge

Oil feed connection from burner
pump

Oil pressure switch in feed line for
lack-of-oil monitoring

Oil return flow connection

Oil pressure switch in return line
for oil overpressure monitoring

Limit switch for oil and gas opera-
tion

Oil flow rate control linkage

Bypass change-over valve (flus-
hing valve)

Pump pressure adjuster for built-
in primary pressure controller

Bypass solenoid valve (flushing
valve)

Return pressure gauge (only
heavy oil)

NOTE:

For heavy oil operation, the oil

control block and oil flow rate controller
are equipped with electric heaters.

Содержание RPD 100

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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