13 Vol.% can be achieved with good flame stability 5.4 6.5 Partial load setting Set selector switch in the contro! panel to partial load. Adapt excess air to the oil throughput of the selected nozzle with the auxiliary switch for partial load. Set the switch point for start of second nozzle with auxiliary switch so that the excess air phase before the switch point is not too large to extinguish the flame, but on the other hand that there is not too much smoke after the connection has been made. Intermediate load setting (only for three stage burners) Set the switch point for start the intermediate nozzle with the auxiliary switch so that the excess air phase before the switch point is not too large to extinguish the flame, but on the other hand that there is not too much smoke after the connection has been made. -12-5.6 Check the ignition (start) load Switch on the burner after the settings above to check If there is a start impact happened {too much smoke). If not, the settings have been made are correct, otherwise, resetting the auxiliary switch point for the start load is necessary. -1B-6 Burner controller(LAL2... and LOK16...) The LAL2... burner control unit is only suitable for the bumers with intermittent operation. for safety reason, at least once in 24 hours, a controlled shut down shall be made. LOK16... controller is suitable for the burners continuously operating without intermittent. The prerequisites for burner start are: 1. The control unit is reset 2. The air damper is closed Servomotor sequence Rogubtor | Nominal load luniion end | Capaciy | Regulator diagram Air "On" prepurge | Mtrtease | reguaton ‘ Fullood ss ‘Switch points IV lgntion oaséfpartal load LaLa Closed ‘ wah ely aons va th geese eo feo toeié Psiton indeator Retultor ereut "288 “a Tima sequence diagram 3 forsenvamoter Bumer fan Sequanoe dageam ol Sequence diagram for 15: Ignition and fuel release 18 cH 6.1 Sequence of operations far bumer controllers ‘Symbols on the lockout indicator The indicator: a-b Start up sequence, b-a Post purge sequence After controlled shutdown. In start position a the sequence switch switches itself off automatically. ‘See symbols on the right chart and the remarks of them below: 4 No start, because a contact has not been made between terminals 12 and 4 or 4 and 5, or because the closed signal has not been supplied to terminal 8 by the limit switch / auxiliary switch. 4 Controlled shut down, because the open signal has not been supplied to terminal -14-& Ra 8 by limit switch. P Lockout, on bumers fitted with air switch because the air pressure signal has not been received at the start of air pressure check. Any pressure failure after this point in time also causes the control to go to lockout Lockout, due to a fault in the flame supervision circuit. < Controlled shut down, because the position signal has not been supplied to terminal 8 by the auxiliary switch. 1 Lockout, because no flame signal has been received on completion of the ‘st safety period. Any pressure failure after this point in time also causes the control to go to lockout! | Lockout, because the flame signal has been lost during burner operation or air pressure failure has occurred, 4 Lockout on completion of control program sequence, due to extraneous light or fault in flame supervision circuit If lockout occurs at any point between start and pre-ignition, which is not marked by a symbol, there is normally a premature or fault} flame signal -15-6.2. Basic wiring diagram for burner controller N Legend ‘A Limit switch for air damper open AL remote indication of fault AR load relay (main relay) AS fuse in bumer control B wire link BR lockout relay BV1 partial load solenoid valve BV2__ full load solenoid valve EK reset button FR flame relay G fan or burner motor LK airdamper LR temperature or pressure regulator LP air pressure switch ( special ) QRB RAR auxiliary switch for minimum damper opening flame sensor(not on LOK16....) temperature or pressure regulator flame sensor ‘servomotor motor sequence switch temperature or pressure switch ignition transformer limit switch in the air damper drive for the shut off position auxiliary switch in the air damper drive to release fuel according to partial load6.3 Legend for switch sequence diagram {1 Pre-purge time t8 Duration of start up sequence 12 Safety time Hor 13. Pre-ignition time 13" Pre-ignition time long Interval to start of air pressure control {11 Air damper run time (Open) t4 Interval between voltage on terminal {12 Air damper run time (Min.) ite t13 Permissible after burner time 15 Interval between voltage on terminal Hé: Interval x OPEN commen for 19-20 air damper NG! Post pumyeitime 120 Interval to the self shutdown of {7 Interval from start up to voltage on tha daquendsiawnian (Raton ail terminal 7 controls) 6.4 Switch times of the burner controller < Ss xill Control output of contacts xve Lockout indicationAy TEMsOLAR & anmt ‘Switching times in seconds. in start up sequence. LAL2.14/ LAL2.25/ LAL2.65/ LOK16.140 LOK16.250 LOK16.650 17 Star up sey for burner motor 2 2 2s 116 Interval from start to OPEN command for air damper 4 5 5 111 Running time for air damper to OPEN position —_ optional optional optional £10" Inter rom stato sao pressure check (if provided) 6 10 10 {1 Pre-purge time with air damper open 10 22.5 67.5 112. Running time for air damper to MIN position ‘optional optional _ optional 13 Pre-ignition time short 2 25 25 13° Prenton in ona fom saarder —fomstatondr tote ndr 12 (1st) safety time 4 5 8 {8n_Postignitn ime ‘0 1s 5 4 Inenatevs ave Q 7s 75 15 Interval between end of 4 and lease of load controller or valve at terminal 20 4 75 78 16 Post pug tine 0 's 1s 13 Permissible after burner time 10 18 15 {20 Interval to the self shutdown of the sequence sith 2 ra 12s ~ Duration of start up (without t11 and 12) 30 475 92.5 * Valid where mains frequency is 50Hz. For 60Hz frequency switching times are reduced by approx. 20%. 6.5 Technical data Nominal voltage-——- 220V-15% to 240V+10% Frequency~ —-- 50Hz -6% to 60Hz +6% Consumption — —--3.5VA Fuse (inbuilt) M6.3/250E (according to DIN 4175,sheet 2) -18-@ amt max. 10A 5A continuous Peaks up to 20A max. External fuse — Permissible input current Permissible loading Of control terminals —~ ---4A continuous, Peaks up to 20A max. Total max. 5A Required switching capacity - between terminals 4 and 5 --- - between terminals 4 and 12 - between terminals 4 and 14 5A continuous peaks of 208 Mounting position Type of protection — Permissible ambient temperature ~ -20 to +60°C at 230V Flame supervision with QRB (not on LOK16) Recommended illumination in Lux -- Response sensitivity of the amplifier ——— Max. possible detector current — Flame indication during operation — Max. permissible detector wiring length Max. permissible ambient temperature Flame supervision with RAR. Minimum required detector current Max. possible detector current Permissible cable length —~ Note: Flame detector wiring must not be bunched together with other wiring, Permissible ambient conditions for electrical components Temperature Humidity Requirements Magnetic compatibility In operation max.80% rel. Directive 89/336/EEC -20°C to +40°C humidity EN 50 081-1 Transport/Storage EN 50 082-1 -40°C to +60°C -19- re. electro-Low Voltage Directive Directive 72/23/EEC EN 60 335© bras 7 Setting the cams limit and auxiliary switches on servomotor 7.1 Setting the switches on 1055/23 servomotor © The air damper position is indicated on a scale of 0° to.90° by a pointer on the shaft. © There is a setting scale between the cam switches. The setting knobs on the cam switch point to this scale with a small pointer and give the switching point of the appropriate switch in relation to the air damper position. The cam switches are set as follows using the setting scale: Cam switches |—Auxiliary switch Dependent on burner rating, between partial Stage 2 valve and intermediate load at 40°. \—Auxiliary switch Dependent on burner rating, 20° Partial load Il—Limit switch Dependent on burner rating, up to 90° Full load IV—Limit switch closed o The limit switches and cam switches are marked in all wiring diagrams with I, II, I and IV and have the function laid down in the connection diagram. The connection diagram is also shown on the cover of the servomotor. There may be a adjusting switch on the Printed Circuit Board of the servomotor. When turned off it, the servomotor will not be controlled by the PCB while the burner is running. So the gear wheel can be uncoupled to do the manual adjusting on the cams for partial load to full load positions. When the adjusting is finished, the adjusting switch shall be turned on. -20-7.2 Setting the switches on 1055/80 servomotor © The air damper position is indicated on a scale of 0° to 90° by a pointer on the shaft © There is a setting scale between the cam switches. The setting knobs on the cam switch point to this scale with a small pointer and give the switching point of the appropriate switch in relation to the air damper position. © The cam switches are set as follows using the setting scale: Cam switches |—Auxiliary switch Dependent on bumer rating, between partial Stage 2 valve and intermediate load at 40°. Auxiliary switch Dependent on burner rating, 20° partial load IIl—Limit switch Dependent on burner rating, up to 90° Full load IV—Limit switch closed o V—Auxiliary switch Dependent on burner rating, at 60° Intermediate load air Vi—Auxiliary switch Dependent on burner rating, at 75° Stage 3 valve ‘The limit switches and cam switches are marked in all wiring diagrams with |, II, Ill, IV, V and VI and have the function laid down in the connection diagram. The connection diagram is also shown on the cover of the servomotor. ‘There may be a adjusting switch on the Printed Circuit Board of the servomotor. When turned off it, the servomotor will not be controlled by the PCB while the burner is running, So the gear wheel can be uncoupled to do the manual adjusting on the cams for partial 2ZA WEDsoLar O sant load to full load positions. When the adjusting is finished, the adjusting switch shall be tumed on. 7.3 Setting the switches on SQN servomotor © The air damper position is indicated on a scale of 0° to 130° by a pointer on the shaft. © The limit and auxiliary switch are set manually on the adjustable cams which indicates the appropriate switch point on a scale between the cam discs. © There is a pointer between the adjustable cams to indicate the angle for each switch position. © The limit switches and cam switches are marked in all wiring diagrams with |, II, Ill and IV and have the function laid down in the connection diagram. The connection diagram is also shown on the cover of the servomotor. Cam switches |—Limit switch(red) Full load Dependent on burner rating, up to 90° II—Limit switch closed(blue) MWI—Auxiliary switch(orange) partial load IV—Auxiliary switch(black) Stage 2 valve o° Dependent on burner rating, 20° Dependent on bumer rating, between partial and intermediate load at 40” Bs8 Maintenance The burner should be checked and maintained regularly and the files such as the maintenance report and operating record cards should be kept in the boiler room. 8.1 Open the burner The bumer should be opened or dismantled by the qualified professional personnel 8.2 Oil pump © Pressure Shall be stable. The value shall be within the initial measured pressure range (1.0 ~1.4Mpa) © Vacuum Shall be lower than 45kPa, It is dependent on the oil level in the oil tank. © Noise There should be not any unusual noise made by the running of the oil pump. In case there is unstable oil pump pressure or unusual running noise during the burner operation, remove the oil supply hose from oil supply pipeline and connect it with the oil supply pipe outlet or a oil tank next to the burner so that the problem which is happened with the pump or oil supply pipeline may be find out. If the problem is in the pump, check the filter inside the pump, otherwise if the problem is in the oil supply pipeline, check the filter of the pipeline and check if air is sucked in the pipeline. 8.3 Filter Check following filters: © Oil fuel filter © Filter inside the pump © Filter for nozzle(s) Clean them or change them by new filters depending on its condition. 8.4 Air blower Check the dust containing inside the air blower casing and fan wheel and ensure the dust is cleaned up. The containing dust will reduce the air blowing quantity in the mixture with fuel so that will effect the combustion result. -23-8.5 Servomotor Check if there is any blocking in the movement of the mechanical parts and loosing screws, check the bearing on the spring band can be smoothly turning, 8.6 Burner head Check and confirm the parts and components are in right shape and on right position, they are cleaned and not shape-changed by high temperature. The attention shall be paid especially at following parts: * The picks of electrodes © The insulation for the electrodes © The high voltage cables for ignition © Nozzle(s) and diffuser * Pressure fuel hose, especially the ends of the hose ¢ The asbestos gasket between the burner plate and the burner flange. 8.7 Nozzles Wash and clean the nozzle filter(s) but never clean the nozzle(s) with a hard piece or dismantle the nozzle. Normally, a nozzle shall be changed after 2~3 years usage. The burner combustion shall be checked after a nozzle change. 8.8 Flame sensor Clean up the glass cover of the sensor from dirt. The sensor can be pull out from its fixing socket. 8.9 Sight glass The sight glass is on the end of the top cover of the burner casing. It shall be kept clean. 8.10 Oil sucking and return hoses Check if there is any damage on the hoses. 8.11 Oil tank Drain out the possible water of dirt in the bottom. Empty the tank and clean it completely after every 5 years usage. 24.8.12 Boiler After check and maintenance, a test run shall be carried out and to find if there is any difference in the operation, especially, any change in the emission temperature and chamber pressure. If there is such a change, the burner shall be re-adjusted, 9 Fault conditions and remedy procedures Ifthe faults occur the basic requirements for correct operation must first be examined: ® Check the electrical wiring to see if the power supply is available. © Ensure the oil supply is available, the shut down valve is open, the oil pump drive is connected and the oil pressure is right. © Check that all components, e.g. thermostats, water level interlocks, limit switches or set correctly © Check if the quantity of air or oil pressure is changed. When it is established that the fault is not due to external conditions, the operation of individual parts must be checked If the burner is stopped by a fault, the burner has to be reset and restarted. Investigate the operation carefully, the fault can be located and remedied efficiently. Condition _ Cause Remedy 1H) No ignition Ignition electrodes too far | Adjust apart Ignition electrodes dirty or | Clean and adjust damp Burner contro! faulty Replace burner control Isolating body cracked Replace Ignition transformer faulty | Replace Ignition cable charred Replace, find and remedy cause 2) Burner motor does | No power Check power supply line not start connecting and switch setting Limit switch off set Check and adjust limit switch Thermal relay of the motor | Adjust, reset acted 2.Capacity graph of HY03 Meal/h 100 200 300 400 500 600700 kW 0 100 200 300 400 500 600 700 800 Kghh 10 20 «30 40 «50600 Capacity graph of HY05 mbar 8 6 4 2 0 2 4 - Mealh 0 200 400 600 800 1000 1200. 1400 KW 0 200 400 600 800 1000 1200 1400 1600 Kgh 0 20 40 60 80 100 120 140faba? Capacity graph of HYO8 Meal/h 600 800 1000 1200 1400 1600 1800 2000 2200 2200 KW 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 Kg/h 80 100 120, 140-160-180 200-220 mbar Capacity graph of HY 10 16 14 10 oN RO McaVh 800 1200 1600 2000 2400 2800 3200 3600 4000 kW 1000 1490 1800 2200 2600 3000 3400 3800 4200 4600 Kyh 80 120 160 200 240-280-320 360 (400 Remarks: ‘The capacity charts show the oil throughput relative to the combustion chamber pressure. They are maximum values measured on idealized test fame tubes. All ratings data given relate to an air temperature of 20°C and an installation elevation of 500m. -29-