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HURST 600 HP Euro Owner's/Operator's Manual

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  • Page 17 As Required by the Provisions of the ASME Code Rules, Section IV 1. Manufactured and certified by Hurst Boiler & Welding Co., Inc., 21971 U.S. Hwy 319 North, Coolidge, Georgia, 31738 (name and address of manufacturer) MOREX, INC., 1609 CROSS BEAM DRIVE, CHARLOTTE, North Carolina, 28217 2.
  • Page 18 We certify that the statements made in this data report are correct and that all details of design, material, construction, and workmanship of this boiler conform to Section IV of the ASME BOILER AND PRESSURE VESSEL CODE. expires "H" Certificate of Authorization no. 17221 January 6, 2018 Hurst Boiler & Welding Co., Inc. Date Signed Name 12/04/2015 (by representative)
  • Page 23 All RGA shipments to HURST must have the RGA number on the outside of the shipping container. Any item not received at HURST within 21 days of the RGA request, will be deemed “not returned” and no credit consideration will be made.
  • Page 24 ASME. All units are first inspected by HURST personnel and then by a “third party” inspector who is a member of the National Board of Boiler and Pressure Vessel Inspectors to verify compliance with all Code requirements.
  • Page 25 BURNER: If supplied by HURST, the burner on your unit will also have a recorded Serial Number that is unique to this unit. Should you need to make an inquiry regarding this burner for service or parts, it is helpful to HURST for you to provide this serial number.
  • Page 26 That power requirement is specific to your unit and will be specified by HURST. It is the responsibility of the customer to supply that power to the panel.
  • Page 27 3. Water column Blowdown: Some hot water boilers may have a blowdown connection on the water column. This should be piped to a point of safe discharge. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 28 Most boiler chemical suppliers can supply the chemicals and the expertise to affect an appropriate method for cleaning your boiler. However, in the absence of such consultation, suggested procedures are outlined below. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 29 15. When filled to the normal level, the boiler should be checked for leaks and may be fired normally. Allow the trapped air to escape the boiler during this initial filling. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 30 14. When filled to the normal level, the system should be checked for leaks and the boiler may be fired normally. Allow the trapped air to escape the system during this initial filling. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 31 PRE START-UP – STEAM HURST assumes that everyone involved with the start-up or operation of this boiler has some training or experience with similar equipment. If not, he/she should not be allowed to be directly involved with the operation or maintenance of the unit. Training is available and should be pursued.
  • Page 32 STARTING FROM COLD HURST assumes that everyone involved with the start-up or operation of this boiler has some training or experience with similar equipment. If not, he/she should not be allowed to be directly involved with the operation or maintenance of this unit. Training is available and should be pursued.
  • Page 33 8:00 AM meter reading = 5000 9:30 AM meter reading = 5040 Difference = Time = 1.5 hour (90 minutes) Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 11 of 31 - Rev 04//07...
  • Page 34 So, 1,771,856 / (33475 x 1.5) = 35.3 HP If you are firing a 35 HP boiler, you are firing it about 1% over rating. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 35 13.270 13.050 12.940 12.620 11.850 13.950 13.720 13.600 13.270 12.460 14.630 14.390 14.270 13.920 13.070 Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 13 of 31 - Rev 04//07...
  • Page 36 0.918 0.922 0.925 0.897 0.905 0.910 0.914 0.917 ATMOSPHERIC PRESSURE 14.4 PSI BAROMETER 29.31 INCHES Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 14 of 31 - Rev 04//07...
  • Page 37 OPERATION – STEAM (Gas or Oil fired) The design of your HURST boiler is such that in general operation, the starting, ramping up, slowing, and stopping is all controlled automatically. (See START UP in this manual). Some of the devices you may find on your unit are the Burner, Firing Rate Controls, Feedwater Controls, Low Water Cutoff, A uxiliary Low Water Cutoff, and High Level Alarm.
  • Page 38 We urge the use of Operational Logs to maintain optimum operational efficiency of your boiler system. Maintaining regular, systematic recordings of operational data such as steam pressure, stack temperature, Feedwater temperature, fuel meter readings, boiler water Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 39 Remember that during periods of cold weather, the piping that supplies fresh water to the system must be protected from freezing. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 40 OPERATION – HOT WATER (Gas or Oil fired) The design of your HURST boiler is such that in general operation, the starting, ramping up, slowing, and stopping is all controlled automatically. (See START UP in this manual). Some of the devices you may find on your unit are the Burner, Firing Rate Controls, Feedwater Controls, Low Water Cutoff, and High Temperature Cutoff.
  • Page 41 As soon as the globe valve is fully open, begin immediately to close it. When it is closed, close the “quick opening” valve. This process should probably lower the level in the gage-glass approximately one-half inch. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 42 Normally, no blowdown is required on a water boiler because there is little make-up of water in a closed system. However, water quality should be checked periodically to determine need for adjustment to your water quality program. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 43 If you are in an area subject to freezing temperatures, be sure to disconnect and drain all connecting lines. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 44 Do not attempt to expand tubes while the boiler is under pressure. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 45 This is the time to contact your local boiler service company and have those leaking tubes repaired. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 46 A water quality consultant can make an analysis of your boiler water and make recommendations for treatment. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 24 of 31 - Rev 04//07...
  • Page 47 This will alert the operator to verify system water quality and adjust treatment as necessary. Shot-type feeders are generally the method used for introducing chemicals into the system. Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com...
  • Page 48 257.32 839.7 1097.0 289.37 0.01734 7.529 258.67 917.9 1176.6 0.4225 1.2255 1.6480 258.49 838.7 1097.2 Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 26 of 31 - Rev 04//07...
  • Page 49 300.30 805.3 1106.6 330.66 0.01777 4.271 301.37 886.5 1187.9 0.4778 1.1216 1.5994 301.03 804.7 1105.7 Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 27 of 31 - Rev 04//07...
  • Page 50 331.10 779.5 1110.6 360.49 0.01812 2.940 332.70 861.8 1194.5 0.5165 1.0507 1.5672 332.18 778.5 1110.7 Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 28 of 31 - Rev 04//07...
  • Page 51 402.40 715.4 1117.8 428.97 0.01908 1.3645 406.66 797.1 1203.7 0.6022 0.8970 1.4992 405.46 712.4 1117.9 Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 29 of 31 - Rev 04//07...
  • Page 52 445.2 673.4 1118.6 467.10 0.0197 0.9283 449.5 755.8 1205.3 0.6487 0.8147 1.4645 449.5 671.7 1118.6 Hurst Boiler & Welding Company, Inc. Start-Up, Operation & Maintenance - Gas or Oil Fired Packaged Boilers www.hurstboiler.com Page 30 of 31 - Rev 04//07...
  • Page 53 Circulation Rates - Hot Water Systems System Temperature Drop - Degrees F BOILER BOILER HP OUTPUT MAXIMUM CIRCULATION RATE - GPM (Btu/Hr/1000) 1005 1340 1675 2010 2345 2680 3350 4185 5025 1005 6695 1339 8370 1674 10045 2009 1005 11720 2344 1172 13400...
  • Page 57 BIMETAL THERMOMETERS FIXED BACK MOUNT (90°) Dial type bimetal thermometer Features anti-vibration design, anti-parallax dial, hermetically sealed case SPECIFICATIONS Dial 2” (50 mm), 3” (76 mm), 5” (130 mm) Anti-parallax dial design Case Stainless steel, hermetically sealed Stem 316 stainless steel, welded to connection Lens Glass Pointer...
  • Page 67 Kunkle Safety and Relief Products Model 537 ASME Section IV, Low Pressure Steam and Hot Water Boilers, ‘HV’, National Board Certified, Safety Valves Features • Extra heavy construction provides long life. • Top guided disc assembly incorporates resilient seal in seating area.
  • Page 68 Kunkle Safety and Relief Products Model 537 Parts and Materials Model 537 No. Part Name Materials Body Seat O-ring BUNA-N Seat Bronze, B584 Alloy 84400 Disc Holder Bronze, B584 Alloy 84400 Insert Ethylene Propylene (EPDM) Diaphragm BUNA-N/Nylon Guide Brass, B36 Alloy C26000 Screw Spring SS, A313-631...
  • Page 69 Kunkle Safety and Relief Products Model 537 ASME Section IV Steam (Hot water boiler) Set Pressure ——————————–––––————— Orifice Area, in ————————–––––———————— (psig) ” 1” ” 2” (0.533 in (0.833 in (1.767 in (3.142 in lb/h BTU/h lb/h BTU/h lb/h BTU/h lb/h BTU/h 689608...
  • Page 70 Kunkle Safety and Relief Products Model 537 Facility Phone: 828-669-3700 Tyco Valves & Controls www.kunklevalve.com Tyco Flow Control (TFC) provides the information herein in good faith but makes no representation as to its comprehensiveness or accuracy. This data sheet is intended only as a guide to TFC products and services. Individuals using this data sheet must exercise their independent judgment in evaluating product selection and determining product appropriateness for their particular purpose and system requirements.

  • Page 71: Standard Features

    INDUSTRIAL TRIDICATORS These instruments have been designed to indicate temperature and pressure in a single unit. With a price that makes this an affordable option for applications where bronze internals are suitable for use, the use of a single ‘tridicator’ saves time during installation, amount of piping required and of course saves money versus using separate gauges and thermometers.

  • Page 73: Table Of Contents

    L4006,7,8; L6006,7,8 ® Aquastat Controllers PRODUCT DATA FEATURES FOR VERTICAL • L4006, 7, and 8 provide Spst switching for high or low MOUNTING AND limit or circulator control. HORIZONTAL • L4006G includes two Spst switches that provide high SENSOR limit and circulator control. INSERTION •...

  • Page 74: Specifications

    ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS SPECIFICATIONS IMPORTANT NOTE: The following specifications are standard. Variances, The specifications given in this publication do not available as options, are listed in Tables 1 and 2. include normal manufacturing tolerances. Therefore, this unit may not exactly match the listed Electrical Ratings (A): specifications.
  • Page 75 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Approvals: Underwriters Laboratories Inc: 1 (25) Remote bulb devices and well-mounted devices shipped without well are component recognized: KNOCKOUT FOR 3/4 (19 ) 5/16 CONDUIT ON ALL MODELS. SIMILAR File No. MP466, Guide No. MBPR2. KNOCKOUT ON BOTTOM FOR L4006A shipped with well, L4006G, L4007A,B;...
  • Page 76 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS 1/2 — 14 IN. NPT 7/8 IN. (22 MM) STANDARD 7/16 KNOCKOUT (2) (11) M8789A 1-1/2 (38) 3 (76) (25) Fig. 4. Approximate immersion well dimensions in inches (mm) for all models except L4006C and L6006B. 1/2 OR 3/4 —...
  • Page 77 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Standard Models: L4006,A,B,C,E,G; L4007,A,B; L4008A,B.E; L6006A,B,C; L6007A, L6008,A,G,H Table 1. L4006, L4007, L4008 Controller (SPST Switching) Specifications. Midscale Switching On Range Differential Temperature Model Application °F (°C) °F (°C) Insertion Rise Available Options L4006A High or low 40°...
  • Page 78 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Table 1. L4006, L4007, L4008 Controller (SPST Switching) Specifications. (Cont.) Midscale Switching On Range Differential Temperature Model Application °F (°C) °F (°C) Insertion Rise Available Options L4006G High limit 100° F to 200° F 10° F (6° C) fixed Horizontal Two switches —...
  • Page 79 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Table 2. L6006, L6007, L6008 Controller (SPDT Switching) Specifications. Midscale Range Differential Model Application °F (°C) °F (°C) Insertion Available Options L6006A Circulator and low 100° F to 240° F 5° F (3° C) fixed Horizontal —...

  • Page 80: Installation

    ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS INSTALLATION The manufacturer usually provides a tapping for insertion of the controller sensing element. This tapping is located at a point where typical water temperature can be measured. Depending on the model, the element is inserted in an When Installing This Product…...
  • Page 81 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS 2. Insert the immersion sensing bulb through the bulb compression fitting. Adjust the adapter clamp so that the clamp fits over the groove at the opening of the bulb compression fitting. SETPOINT 3. Tighten the adapter clamp screws so that the Aquastat INDICATING DIAL Controller is firmly attached to the bulb compression DIFFERENTIAL...
  • Page 82 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS CLAMP B CLAMP SCREWS (2) CLAMP A BULB BULB COMPRESSION SEALING FITTING WASHER JAWS SPREAD JAWS TO FIT OVER RIDGE ON WELL SPUD INSERTION LENGTH SCREWDRIVER APPROX. 3-3/16 IN. (81 MM) SPLIT SLEEVE M8815A MOUNTING CLAMP Fig.
  • Page 83 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Mounting Remote Bulb Models For Outdoor Air Sensing These models have a 5 ft (1.5 m) capillary that establishes the maximum distance between the case and the outdoor mounting. Install the bulb on the outside of the building in the shield provided (See Fig.
  • Page 84 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Mounting on Suction Line Wiring 1. In cooling units with more than one suction line, place Disconnect power supply before beginning installation to the sensing bulb on the common line. prevent electrical shock or equipment damage. 2.
  • Page 85 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS 24 VOLT PROTECTORELAY THERMOSTAT CONTROL L4006A OR L4007A (HOT) HIGH LIMIT RA832A ® AQUASTAT L4006A OR L4007A HIGH SWITCHING RELAY (HOT) CONTROLLER LIMIT CONTROLLER 24 VOLT THERMOSTAT IGNITION IGNITION CIRCULATOR L4006B OR L4007B CIRCULATOR OIL VALVE BURNER ®...
  • Page 86 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS L4006 HIGH LIMIT (HOT) L2 SERIES 80 CONTROLLER THERMOSTAT MILLIVOLTAGE THERMOSTAT L6006 CIRCULATOR MILLIVOLTAGE VALVE OPERATOR LOW LIMIT SAFETY CONTROL SHUTOFF PILOT PILOTSTAT¨ OPERATOR BURNER POWER UNIT COIL L8148A POWER UNIT COIL M1156A Fig. 27. Typical Powerpile System wiring diagram. LOW VOLTAGE HEATING LOAD LINE VOLTAGE...

  • Page 87: Adjustments

    ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Low Limit Controller R-B terminals provide low limit switching function (contacts open at set point on temperature rise). Maintains minimum boiler temperature for domestic hot water. Turns on boiler at temperature setting, less differential. BREAKS R-B MAKES R-W ON RISE LEFT SWITCH...
  • Page 88 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Adjust the control point to correspond with the boiler Table 3. Temperature Adjustments. manufacturer recommendations. To adjust, insert a screwdriver in the slotted screw type head located beneath the Difference Between Desired window in the cover. Turn the scale to the desired control point. Room Temperature and Case Temperature Reduce Dial Setting...

  • Page 89: Checkout

    ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS CHECKOUT Check to make certain that the Aquastat Controller is properly installed and adjusted. Put the system into operation and observe the action of the controller through several cycles to make certain it provides proper control of the system as WARNING described in the OPERATION section.

  • Page 90: Material Safety Data Sheet

    ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS MATERIAL SAFETY DATA SHEET Section 1. Product And Company Manufacturer: Honeywell Inc., 1985 Douglas Drive North, Minneapolis, MN 55422. Identification Date Released: October 8, 1999 Product Name: Heat Conductive Compound NFPA Ratings: MSDS ID: DS9021 Health 0;...
  • Page 91 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Section 6. Accidental Release Measures Reactivity: Hazardous polymerization will not occur. Scrape up and dispose of as solid waste in accordance with Incompatibilities: Strong oxidizing agents and halogens. state and federal regulations. Hazardous Decomposition Products: Carbon dioxide, Section 7.
  • Page 92 ® L4006,7,8; L6006,7,8 AQUASTAT CONTROLLERS Automation and Control Solutions Honeywell International Inc. Honeywell Limited-Honeywell Limitée 1985 Douglas Drive North 35 Dynamic Drive Golden Valley, MN 55422 Toronto, Ontario M1V 4Z9 customer.honeywell.com ® U.S. Registered Trademark © 2006 Honeywell International Inc. 60-2104—10 J.I.
  • Page 97 M2148 1425EN Operation and maintenance manual KP-300 M – 700 M-II WD32, WD33 Read these instructions carefully before installation, use, or maintenance...
  • Page 99 Contents Introduction 1.1. Conventions in this manual................3 1.2. General information..................3 1.3. Watching boiler room..................4 1.4. Handling and storing..................5 Operation 2.1. Burner operation................... 6 2.2. Switch panel....................9 2.3. General description of burner operation.............10 2.4. Site diagram, example................12 2.5. Legend to time sequence diagram symbols..........13 2.6.
  • Page 100 5.1. Burner maintenance..................48 5.2. Oil filter......................49 5.3. Nozzle valve operation and maintenance RPL-1........50 5.4. Oil regulator....................51 5.5. Dismounting and changing burner motor........... 53 5.6. Dismounting and changing servomotors............ 54 5.7. Testing flame detector................56 5.8. Fault history....................56 5.9.

  • Page 101: Introduction

    1. Introduction 1.1. Conventions in this manual Read these instructions carefully before installation, commissioning, operation or maintenance of the device. The given instructions must be followed. Throughout this manual, the following three symbols are used to point out very important information: Be careful.

  • Page 102: Watching Boiler Room

    IN CASE OF FIRE OR OTHER EMERGENCY ● Switch off the main switch. ● Close main fuel shut-off valve. ● Take appropriate actions. ● Contact operation controller. If the burner control system, including all related components, does not support continuous operation, perform a controlled shutdown every 24 hours to ensure safe operation.

  • Page 103: Handling And Storing

    1.4. Handling and storing Store device and its equipment in a dry and airy place. Protect device from dust and humidity. Follow storing and transporting instructions included in the package. Documentation is part of the product, and it must be passed on together with device, also with a second hand product.

  • Page 104: Operation

    2. Operation 2.1. Burner operation WD32-34 system ver. 1 The assembly may vary depending on the scope of delivery. WiseDrive system In the WiseDrive system burner operation is controlled and supervised by burner control integrated to burner. Burner control adjusts air and fuel ratio. The system includes operating and display unit for local use.
  • Page 105 See also manufacturer instructions for setting parameters. PC application The main functions of the LSB remote program application are: ● setting parameters, ● creating ratio curves, ● data collection, ● fault diagnostics, ● backup copying, and ● manual control. Communication between PC and BT300 system is executed with LSB bus interface to USB connection.
  • Page 106 Servomotors Servomotors drive air dampers, gas butterfly valve and oil regulator. With the help of servomotors electronic air and fuel ratio control is carried out, controlled by burner control. Lamtec motor ver. 2 ● Static electricity can damage servomotor. ● Do not dismount servomotor. Do not interfere with or modify unit or equipment connected to it.

  • Page 107: Switch Panel

    Operating and display unit The WiseDrive system operating and display unit for local use is used for monitoring and adjusting settings. User interface is implemented with graphics and animated symbols. Control panel photo ver. 2 For backup copying you need a PC application. Flame detectors  ...

  • Page 108: General Description Of Burner Operation

    1. Control panel A100 2. Control switch S1/H1 3. Fuel selector switch S2 (optional) D031323 ver. 1 Control switch S1 Switch position State 0 - STOP Control voltage is cut off from burner automation and burner is shut down. 1 - CONTROL Control voltage is switched on to burner automation (burner control, servomotors).
  • Page 109 Oil pump Differential air pressure switch Pressure gauge Servomotor, air Solenoid valve, NC Flame detector Solenoid valve, NC Servomotor, oil Pressure gauge Pressure regulating valve Regulating valve Oil to burner Non-return valve Oil from burner Burner startup: Pre-purging, ignition During pre-purging, the burner fan ventilates the boiler and smoke flue. The fan manages to create a full-air pressure before oil inlet.

  • Page 110: Site Diagram, Example

    Ignition ends after time determined by the burner control. Flame burns with set ignition load. Burner models without pilot flame function start up directly to the main flame by opening double solenoid valves (V1 and V2). Burner operation During burner operation, the capacity controller controls servomotors, which adjust butterfly valve and air dampers between partial load and full load according to the capacity demand.

  • Page 111: Legend To Time Sequence Diagram Symbols

    5. Oil booster 12. Max. low pressure -0,3 bar 6. Gas/air separator 13. Oil pressure 1 - 5 bar 7. Pressure regulating valve   A Oil to booster B Oil to burner C Oil from burner Pumping unit minimum output equation: Required minimum output [kg/h] = (oil flow to be burned kg/h + 150 kg/h)×1,2 2.5.

  • Page 112: Operation

    2.6. Time sequence diagram, oil use without ignition gas Time sequence diagram for oil (without ignition gas) 11-3 ver. 1 3) Irrelevance time oil P 765 affects safety interlock chain oil and oil pressure min. when ignition valve or oil valve opens. Safety interlock chain boiler X34 Oil regulating valve Safety interlock chain burner...
  • Page 113 ● Control unit safety features are activated. ● Fan motor is started (X25). ● Servomotors drive to the pre-purge position. 0021 ver. 2 ● The differential air pressure switch contact closes when the required air pressure is reached. If the required air pressure is not reached, a safety shutoff will be initiated. Control is active until a controlled shutdown.
  • Page 114 ● Safety time t9 ends. ● Ignition ends (X04). ● Flame signal has to be reached from the end of the safety time to controlled shutdown. ● Main flame burns at set ignition load. Servomotors drive to the minimum capacity position. 0021 ver.
  • Page 115 0023 ver. 2 ● Servomotors drive to post-purge position. ● Lockout, if the burner control receives flame signal. ● Fan motor stops at the end of the phase. ● The safety functions of burner control are powered down at the end of the post- purge phase.

  • Page 116: Installation

    3. Installation 3.1. Installing and mounting burner Burner mounting ● Prepare boiler front plate according to the given dimensions. ● Coat bolt threads with graphite-bearing grease prior to fitting. ● Install burner so that motor shaft lies horizontally. Do not install burner upside down. ●...

  • Page 117: Lifting The Burner

    Burner Dimensions mm     L1 for adjustable combustion head 300 M 300 M-II 300 M-III 400 M 500 M 600 M 700 M 700 M-I 700 M-II 3.2. Lifting the burner Lifting instructions for models 300-700 1. Protective cover 2.

  • Page 118: Burner Hinges

    3.3. Burner hinges Turning the burner ver. 4 As standard the burner swings to the left. Right side hinging is delivered on request only. Switch off electric power from your burner before burner swing- out. 3.4. Connecting to oil line Two-pipe system Burner is equipped for two-pipe system.

  • Page 119: Electrical Connections

    3.5. Electrical connections Connect burner according to the electrical diagrams delivered with burner. Adhere to general and local standards and regulations as well as requirements set on the connections of electrical equipment. Configure burner installation with a switch that allows it to be disconnected from the low-voltage supply mains. Plant grounding must be in order before commissioning burner.

  • Page 120: Commissioning

    4. Commissioning 4.1. First start-up Installation and commissioning of the burner may be carried out ONLY BY AUTHORISED PERSONNEL. Keep boiler door closed while starting burner, and during burner operation. First start-up The following should be checked before first start-up: ●...

  • Page 121: Nozzle Selection

    When adjusting burner, make sure that the minimum and the maximum values for burner capacity are not exceeded. Values are marked on the type label. 4.2. Nozzle selection Fuel consumption by boiler capacity P = boiler capacity, kW µ = boiler efficiency, 0,80-0,95 q = P/µ...
  • Page 122 *) Oil quantity return pressure10 bar (1,0 MPa) When using any other oil pump pressure as shown in table, the throughput of nozzle is: PAINEKAAVA1 ver. 2 A = Table value P1 = 20 bar (Fluidics) P2 = Oil pump pressure For example: nozzle 12-W1 No.
  • Page 123 When using any other oil pump pressure as shown in table, the throughput of nozzle is PAINEKAAVA1 ver. 2 A = Table value P1 = 25 bar (Fluidics) P2 = Oil pump pressure For example: Nozzle 12-W2 No. 100, oil pump pressure 30 bar (3,0 MPa) ⇒ throughput of nozzle is: 30 ba r 100 kg/h x...

  • Page 124: Setting Ignition Electrodes

    Ma x kg/h Min = PAINEKAAVA4 ver. 2 Oil pump operating pressure (atomizing pressure) in heavy fuel oil is 2500 - 3000 kPa (25 - 30 bar). Oil pump operating pressure (atomizing pressure) in light fuel oil is 2000 - 2500 kPa (20 - 25bar).

  • Page 125: Adjusting Pressure Drop In Combustion Head

    D020507 ver. 2 H 8 mm K 9 mm L 10 mm M 3 mm 4.4. Adjusting pressure drop in combustion head Effect of the adjustment ring Adjustment ring position effects on pressure drop in combustion head. Adjust pressure drop by moving adjustment ring back and fort thus altering the gap between adjustment ring and diffuser plate.
  • Page 126 Combustion head pressure drop minimum: ● gas use 2 mbar ● heavy fuel oil 4 mbar ● light fuel oil 3 mbar ILMANNOPEUS ver. 3 If adjustment ring position has to be altered in relation to diffuser disc, air velocity and quantity in combustion head will change. Check combustion values by flue gas analysis and, if necessary, adjust combustion air quantity to be adequate.

  • Page 127: Adjusting Combustion Differential Air Pressure Switch

    1. Combustion head extension 2. Adjustment ring 3. Diffuser disc 4. Ignition electrode 5. Nozzle Adjusting combustion air Adjust combustion air volume with adjusting cam. 1. Check surplus oxygen level from gas flue after every adjustment with a flue gas analysator.

  • Page 128: Adjusting Supply Oil Pressure

    1. Low pressure connection, fan suction 2. High pressure connection, fan blow If pressure difference does not rise above switch setting value burner shuts down. Differential air pressure switch should be set to trigger before CO-concentration of combustion product exceeds 1 vol%, 10 000 ppm. Burner size Factory setting mbar 200 -300...
  • Page 129 The pump is self-priming. The pump is intended for use in two- pipe system (=ring main system). Pay attention to the instructions provided by the pump manufacturer when dimensioning the pipeworks. If the atomizing pressure during capacity change from max. to min.
  • Page 130 TECHNICAL DATA PUMP AFI Max oil inlet pressure to burner 5 bar Inlet oil viscosity range 4 - 70 mm²/s (cSt) Min oil inlet pressure to burner 2.5 bar or higher depending on oil temperature at the pump. See illustration. Inlet oil maximum temperature + 150 °C Oil pump T...

  • Page 131: Adjusting Atomizing Pressure

    Oil pump TA / TAR / UHE 1. Oil suction connection 2. Oil to nozzle 3. Oil return connection 4. Pressure adjustment 5. Protective cap 6. Oil inlet pressure/gauge port 7. Pressure gauge connection plug / air venting 8. Opening for bypass plug A212ZTA ver.

  • Page 132: Oil Pump Coupling Components And Adjusting

    TVSAADINDANFOSS ver. 3 TVSAADIN ver. 2 Regulator valve option 1 Regulator valve option 2 Oil from pump Protective cap Oil to nozzle Pressure regulation Return oil Pressure gauge connection 4.9. Oil pump coupling components and adjusting Oil pumps: J, E, PON, TAR, T, TA and UHE 1.

  • Page 133: Operating And Display Unit Adjustments

    Oil pump: AFI BOWEX ver. 3 1. Hub 2. Sleeve 3. Set screw Set the distance between hubs. See image. Note the correct direction of the hubs. 4.10. Operating and display unit adjustments Scrolling menus For scrolling and changing set values of operating and display unit menu use six buttons shown on display.

  • Page 134: Display Menus

    1. Display 2. Esc 3. Arrow keys 4. Enter Control panel ver. 2 Scroll menus with arrow keys. Select desired submenu by pressing Enter -button. Return to higher menu level by pressing Esc -button. Menu structure Menus are divided into three operating levels: ●...
  • Page 135 A. Main menu 0000 Burner stop ver. 3 0000 Burner running ver. 3 Burner off Burner on Menu code: 0000 Fuel: OIL or GAS User level: locked (1) or open (2) Upper pillar: burner capacity, % Lower pillar: flame on/off and intensity B Main menu path 0001 ver.
  • Page 136 C2 Manual menu path User can scroll and change values of burner’s manual control. 2000 ver. 3 This function bypasses startup input (X10) and is active only staying in this menu. C3 service menu 3000 ver. 3 Changing the user level 1.
  • Page 137 Submenus of C3 service menu Program sequences 3200 ver. 3 ● duration of pre-ventilation, post-ventilation and valve leakage test ● location of valve leakage test in sequence ● ignition gas valve selection Actuating outputs 3300 ver. 3 ● Configuration of actuating outputs Ratio curve-editor 3400 ver.

  • Page 138: Manual Start Up And Servomotor Position Checking

    Setting parameters for controllers 3700 ver. 3 ● Parameters for load controller module (LCM) ● Parameters for O2- and CO-controllers Changing password, service level 1 3800 ver. 3 Display settings 3900 ver. 3 ● brightness, contrast, waiting time for screen saver 4.12.

  • Page 139: Ignition Position

    3400 ver. 3 Start up on manual drive Check that interlocks and alarms are reset. Activate burner start up on manual drive from the control panel’s point Pre-purge position checking Factory setting of pre-purge position is fully open (999). Resetting is possible only by PC-program.

  • Page 140: Setting Ratio Curve

    Check combustion values of ignition capacity with flue gas analysis. 4.14. Setting ratio curve Creating curve point individually There can be max. 11 curve points. Setting ratio curve is carried out from the control panel menu 3400 numbered ver. 2 fuel (set of curves) set condition level 2 (burner manufacturer)

  • Page 141: Capacity Range

    Ignition , 200, 250, 300, 400, 500, 600, 700, 800, 900, 999 With turning angle 70% of gas regulator valve, the largest gas amount flow is reached. If gas amount consumption is not adequate enough by the time, check and adjust pressure regulator’s outlet pressure to be higher, if necessary.

  • Page 142: Setting Load Controller Parameters

    0 = no CAN terminator 1 = CAN terminator active DIP-5–6, product family DIP-5 DIP-6 Product family DIP-2–4, choosing temperature sensor DIP-2 DIP-3 DIP-4 Sensor PT100, boiler water temperature PT1000, boiler water temperature PT100, outside temperature PT1000, outside temperature PT100, flue gas temperature PT1000, flue gas temperature...
  • Page 143 0060 BT300 Reset time 15 (w) / 20 (s) 0061 BT300 Representation of actual value and set-point for 1 (w) / 2 (s) load regulator 0062 BT300 4 mA corresponds to x units 0063 BT300 20 mA corresponds to x units Pressure transmitter max.

  • Page 144: Load Controller Use

    characteristic control process control mode start/up procedure I-factor higher decrease of stronger reaction faster start-up with attenuation with tendency to tendency to osciliate osciliate I-factor lower increase of weaker reaction slower start-up attenuation less tendency to osciliate I-factor too high I-factor diagram ver.
  • Page 145 0000 modified ver. 1 ● measurement unit, ºC/bar ● load controller actual value, I = 105 ºC ● load controller set value, S = 100 ºC Setting parameters for load controller   3700 ver. 3 3710 modified ver. 1 ● %-PID load controller settings  ...

  • Page 146: Maintenance

    5. Maintenance 5.1. Burner maintenance Close all burner’s safety covers with all screws before start-up. Use appropriate tools. Cut off electric current from burner, and close manual shut-off valves always before any maintenance work. Cutting power is adequate when just inspecting the device. ●...

  • Page 147: Oil Filter

    9. Clean burner from dust and moisture. 10. Check combustion characteristics by flue gas measurements regularly or when sooting boiler. 11. Check gas pipings for leaks. 5.2. Oil filter Oil filter components 1. Mantle 2. Cover 3. O-ring 4. Gasket 5.

  • Page 148: Nozzle Valve Operation And Maintenance Rpl-1

    4. If there is dirt in filter, it can be removed by for e.g. vacuuming. Check O-ring and washer condition. 5. Lock plug with nut. 6. Place filter element back into filter, and put cover on. 7. Fasten cover with fastening screw to a torque of 25 - 30 Nm. 5.3.

  • Page 149: Oil Regulator

    RPL-1 Operation principle The opening of the nozzle valve is controlled by solenoid valves and oil pressure. The force of oil pressure on piston must exceed the force of the spring. The pressure of the spring closes the nozzle valve, when oil pressure stops having effect on nozzle valve. The needle valve of the nozzle closes.
  • Page 150 Front flange Hexagon socket-head screw Hexagon socket-head screw     O-ring Oil to valve X-ring Oil from valve Oil regulator components for model 700 D023713 ver. 1 Body Needle bearing Dosing shaft Hexagon socket-head screw Flange Hexagon socket-head screw Connector nipple Hexagon socket grub screw Compression spring Thrust bearing (ring)

  • Page 151: Dismounting And Changing Burner Motor

    5.5. Dismounting and changing burner motor Cut off electricity from burner and ensure the motor has no voltage. Fan cross section 1. Motor 2. Fan wheel 3. Fixing sleeve 4. Wedge 5. Fixing screw of fan wheel 6. Base bushing 7.

  • Page 152: Dismounting And Changing Servomotors

    5. Screw down fan wheel with fixing screw to motor shaft. 6. Place motor and attach screws. 7. Connect electrical cable to motor. 8. Connect burner to the mains. Check motor rotation direction. 5.6. Dismounting and changing servomotors Disconnecting cables 1.
  • Page 153 5. Make sure that the shaft coupling aligning screw is aligned with the servomotor axel. 6. Make sure that the clamping screw of the shaft coupling is securely fastened. 7. Mount the new servomotor. 8. Tighten the servomotor fixing screws. 9.

  • Page 154: Testing Flame Detector

    5.7. Testing flame detector Testing flame detector function Test flame detector function, when checking or servicing burner. METHOD RESULT Look ts-time from the cover of control Burner function should end to a lockout. unit and time sequence diagram. Measured time should be consistent with the Block the detector from light and ts-time printed on control unit cover.

  • Page 155: Troubleshooting

    Lockout means emergency shutdown. 5.9. Troubleshooting Always check first basic operation requirements. ● Check control and supply voltage. ● Check that all regulating and control devices are correctly set. ● Check that safety devices are in normal operating condition. ● Check that burner is getting fuel. ●...
  • Page 156   Faulty differential air Change. pressure switch. Display 10, 15. Fan motor starts, lockout Jammed servomotor. Check and adjust. during pre-purge. Servomotors do not reach desired position. Fault code 241, 251, 261, 271, 281   Faulty differential air Change. pressure switch Fault code 613 Lack of air pressure , fault code 613 CONDITION...
  • Page 157   Faulty burner control Check fault code. Replace. Lockout during pre-purge. Faulty flame detector Change.   Faulty burner control Check fault code. Replace.   Incorrect flame signal Block extraneous light. because of extraneous light Lockout in shut-down Faulty or aged flame Change.

  • Page 158: Technical Data

    6. Technical data 6.1. Type labelling on Oilon burners Example of type labelling GRP-150 M WD32 Burner label WD ver. 2 Label element 1: Fuel Light fuel oil Heavy fuel oil Gas, light fuel oil Gas, heavy fuel oil Label element 2: Burner size categorization Label element 3: Method of control Two-stage Three-stage...

  • Page 159: Burner Technical Data

    6.2. Burner technical data Burner data BURNER KP-300 M KP-300 M-II KP-300 M-III Capacity kW, oil 770 - 4030 950 - 4500 1200 - 5000 Capacity kg/h, oil 70 - 340 80 - 380 101 - 421 Nominal motor output kW Nominal oil pump motor output kW Oil inlet pressure to...

  • Page 160: Burner Control Technical Data

    Other technical data and requirements Fuel, oil use Light fuel oil Efficiency, light fuel oil 1 kg ≈ 11.86 kW efficiency, when heat value is 42.7 MJ/kg Max. demand for combustion air, oil 15 m³/kg Control voltage 230 V (-15%...+10%) 50 Hz / 60 Hz 1-phase Control voltage on request 110 V (-15%...+10%) 50 Hz / 60 Hz 1-phase Degree of protection...
  • Page 161 Burner control BT 300 terminal diagram BT300 inner circuit ver. 2 user interface UI 300 LSB optional continuous output 1, for example air damper continuous output 2, for example gas damper continuous output 3, for example oil SIC = safety interlock chain 230V AC 47 - 63Hz external fuse protection required (max 10A slow-blow) 230V AC for power supply to external devices Maximum cable length:...

  • Page 162: Servomotor Technical Data

    6.4. Servomotor technical data Servomotor 662R5001 662R5003 662R5010 Interface LSB (Lamtec system LSB (Lamtec system LSB (Lamtec system bus) bus) bus) Turning angle 90° 90° 90° Accuracy ±0,2° ±0,2° ±0,2° Torque, operation/ 1.2/0.8 Nm 3/2.8 Nm 9/6 Nm hold Running time/90 15 s degrees Protection degree...

  • Page 163: Capacity And Backpressure Curves

    6.6. Capacity and backpressure curves Capacity and backpressure curves KP300700MIITVP ver. 3 1 kg/h = 11,86 kW 6.7. Flame detector technical data FLAME DETECTOR Min. required detection current with 230 VAC voltage 95 µA Max. detection current 160 µA Instrument’s +pole Detector cable length in the same cable as the control lines max.
  • Page 164 66 (65) M2148 1425EN...
  • Page 166 OILON GROUP P.O. Box 5 FI-15801 LAHTI FINLAND Tel: +358 3 85 761 Fax: +358 3 857 6239 Email: info@oilon.com www.oilon.com...
  • Page 167 PÄIVÄYS: DATE:2015-10-09 DRAWING NO PIIRUSTUSNUMERO SIVU MUUT. PÄIVÄYS PAGE REV. DATE NIMITYS TITLE NIMITYS TITLE 110016 2015-10-09 DRAWING LIST LEHTILUETTELO 110016 2015-10-09 CABLE DIAGRAM KAAPELOINTIKAAVIO 110016 2015-10-09 CABLE DIAGRAM KAAPELOINTIKAAVIO 110016 2015-10-09 WIRING DIAGRAM JOHDOTUSKAAVIO 110016 2015-10-09 WIRING DIAGRAM JOHDOTUSKAAVIO 110016 2015-10-09 WIRING DIAGRAM...
  • Page 169 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 EI SISÄLLY OILONIN EI SISÄLLY OILONIN TOIMITUKSEEN TOIMITUKSEEN 3P+N+PE 60Hz 380V 1P+N+PE 60Hz 110V...
  • Page 171 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 ASIAKAS KAAPELOI KATTILAN PAINE KATTILAN LÄMPÖTILA KATTILA MUST BE FIXED +BOILER KORKEA...
  • Page 173 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTIN BURNER POLTINOHJAIN KYTKENTÄKOTELO BURNER CONTROL UNIT CONNECTION BOX BT320 LAMTEC KAAPELOITU TEHTAALLA...
  • Page 175 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTIN BURNER KYTKENTÄKOTELO CONNECTION BOX POLTINOHJAIN BURNER CONTROL UNIT BT320 LAMTEC 2x0.75 ÖLFLEX 3G0.75...
  • Page 177 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTIN BURNER HUOLTO LIITIN KYTKENTÄKOTELO SERVICE CONNECTOR LISÄVARUSTE CONNECTION BOX ACCESORIES...
  • Page 179 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTINOHJAIN BURNER CONTROL UNIT BT320 LAMTEC POWER SUPPLY ALARM OUTPUT COMBUSTION AIR OIL PUMP...
  • Page 181 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTINOHJAIN BURNER CONTROL UNIT BT320 LAMTEC GAS PRESSURE LOW/ FAULT RELEASE BURNER ON SAFETY INTERLOCK CHAIN...
  • Page 183 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTINOHJAIN BURNER CONTROL UNIT BT320 LAMTEC CAPACITY CONTROLLER FUEL VALVE 1 FUEL VALVE 2 FUEL VALVE 3/...
  • Page 185 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 POLTINOHJAIN BURNER CONTROL UNIT BT320 LAMTEC USER INTERFACE CONTINIUOUS OUTPUT 1 CONTINIUOUS OUTPUT 2 UI300...
  • Page 187 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 HUOLTO LIITIN LISÄVARUSTE POLTINOHJAIN SERVICE CONNECTOR ACCESORIES BURNER CONTROL UNIT BT320 LAMTEC A200...
  • Page 189 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 LISÄVARUSTE ACCESORIES A200 TEHONSÄÄTÖ MODULI POWER CONTROL MODULE LCM100 LAMTEC ANALOG FLUE GAS...
  • Page 191 Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Versio Muuttaja Vuosi Vko Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week Rev. Drawn Year Week p_lomakkeet.92 PS1160 A100 S1/H1 0-1- A200 LISÄVARUSTE ACCESORIES Tilaaja Valmiste Nimitys...
  • Page 193 PÄIVÄYS: DATE:2015-10-09 SIJAINTI LOCATION TUNNUS NIMIKE DESCRIPTION TYYPPI TYPE TEKNISET TIEDOT TECHNICAL DATA VALMISTAJA MANUFACTURER TTKOODI MAT.CODE PCS PGE LKM SVU BURNER LIITINSARJA (BTxxx) CONNECTOR SET (BTxxx) 667R0900-2 LAMTEC 36106039 BURNER KESKUSYKSIKKÖ CONTROL UNIT BT330 110V 667R1331-1 LAMTEC 36106066 BURNER A1/A200 CAN-BUS CABLE CAN-BUS CABLE...
  • Page 195 Commisioning  Error Codes BT300 Supplement Sensors and Systems for Combustion Engineering...
  • Page 197 Table of Contents Table of Contents GENERAL INFORMATION ........3 Validity of these Instructions.
  • Page 198 General Information General Information Validity of these Instructions This is an additional document related to the basic documents of the LAMTEC burner-man- agement-system below. It is valid only in combination with the use of the concerned operating manual. The information contained in this document refer to the software versions BT300 v2.0.0.0 and UI300 v1.0.0.0...
  • Page 199 List of Fault Codes List of Fault Codes Fault Code Description Unknown fault (internal error) Pre-ventilation signal is still active. Parasitic light detected Flame blow-off during ignition Flame blow-off during operation Flame signal does not appear during the first safety time Flame signal extinguishes during stabilization time Flame signal extinguishes during first safety time Flame signal extinguishes during the second safety time...
  • Page 200 List of Fault Codes Fault Code Description Channel feedback changes too fast Channel (x) Recirculation damper is deactivated Channel (x) Short circuit of LDR flame detector First monitoring band exceeded for to long Channel (x) First monitoring band fall short for to long Channel (x) Second monitoringband exceeded for to long Channel (x)
  • Page 201 List of Fault Codes Fault Code Description Fault shut-down due to a missing bruner maintenance Smallest valid O value deceeded Outpout for internal firing-rate is defective Difference of the burner firing-rate values between main proces- sor and watchdog processor is too large Correction ...
  • Page 202 List of Fault Codes Fault Code Description Oil pressure too low Invalid change of the operation mode Internal state information Invalid signal combination at input terminals during operating mode "Burner OFF" Invalid signal combination at input terminals during operating mode "Burner Ready" Invalid signal combination at input terminals during operating mode "Pre-ventilation"...
  • Page 203 List of Fault Codes Fault Code Description Pre-ventilation period falls below the minimum Leakage test: Main gas valve 2 opens for too long Leakage test: Main gas valve 1 leaky Leakage test: Main gas valve 1 opens for too long Leakage test: Main gas valve 2 leaky Flame monitoring: Flame burns for too long after shutdown Program monitoring time exceeded...
  • Page 204 List of Fault Codes Fault Code Description Directly controlled channel runs to an invalid position, i.e. a chan- Channel + Date nel that is not deactivated nor controlled by fuel/air ratio control Fault interlocking active! Reference no. The gap between two remote fault releases is too short Power failure Output terminal for oil valve defective Output terminal for ignition transformer defective...
  • Page 205 Assignment of Configuration fault 107 Assignment of Configuration fault 107 Description Too many channels in configuration parameter 804. No channel at all configured. Permanent ignition burner configured (parameter 302, 303), but no ignition flame monitoring device present  (parameter 800). Prepurge suppression via external signal not implemented.
  • Page 206 Assignment of internal fault 999 Assignment of internal fault 999 Description 0-1999 internal faults generated from within System API return value of m_PwrOn_uiInitAPI() m_PwrOn_uiInitAPI() failed CRC32 check of ROM failed Cyclic CRC32 check of ROM during runtime failed Erroneous State State machine for CRC32 check during runtime ran into an invalid state m_PwrOn_bLoadEEPROM() failed Vorgabe...
  • Page 207 Assignment of internal fault 999 Description sIO.sIn.ulInputsN Detected positive half-wave on terminal input! input status received from UP Different input status between controllers The readback input of the fuel selection relais contacts in the dual fuel is invalid. DFM probably defect. Input status of digital input on HP and UP is inconsistent (>20ms) ucPin2Test Pin short circuit test detected an error!Currently tested pin not configurated...
  • Page 208 Assignment of internal fault 999 Description sWDog.ulReleasePtrn1 Trigger release patterns are invalid! eFeedIndex Invalid Feed Index eTriggerCtrl Invalid Trigger Mode No valid watchdog trigger received (frequency or duty cycle invalid) uiErrorCode Fault from LPC_API error handler Invalid entry in iStoerResRam uiMaskedFaultCode uiMaskedFaultCode out of range! 1200...
  • Page 209 Assignment of internal fault 999 Description 1454 psActuator->ucSANumber H_SA_STEPCALC_INVALID_DIRECTION 1455 psActuator->ucSANumber H_SA_STEPCALC_WRONG_STATUS 1460 U_SA_INTERFACE_INVALID_ACTUATOR_TYPE 1461 U_SA_INTERFACE_INVALID_DIRECTION 1470 psActuator->ucSANumber U_SA_FEEDBACK_INVALID_DIRECTION 1471 psActuator->ucSANumber U_SA_FEEDBACK_INVALID_DIRECTION 1472 psActuator->ucSANumber U_SA_FEEDBACK_WRONG_FEEDBACK 1480 psActuator->ucSANumber U_SA_REFERENCE_SEARCH_INVALID_ACTUATOR_TYPE 1490 psActuator->ucSANumber psActuator->ucSANumber Invalid! 1500 Timeout while sending ICOM command 1501 Timeout while waiting for ACK of ICOM command 1502 Timeout while waiting for end of actuator initilization 1503...
  • Page 210 Assignment of internal fault 999 Description 2308 Cold check 2309 Cold check 2310 Invalid state 2350 - Cold check 2354 2400 Attempt to write to a modbus register 2401 Modbus register described 2500 Parameter with access level > 4 2600 Does not find the operating mode 2601 Transfer forbidden...
  • Page 211 Assignment of internal fault 999 Description 4000-4999 Internal faults generated from within Application (Fuel/Air Ratio Control) 4000 No curve point to the load of the ignition point 4001 ucPIdx_R >= ucPunktAnzahl 4100 sRampe.ucState invalid value of sRampe.ucState 4200 ucVBMode invalid value of ucVBMode 4302 No active air channel is defined (parameterization error) 4400...
  • Page 212 Assignment of internal fault 999 Description 4717 ucKnr Transferred channel number out of the permitted range 4800 uiActTmr ucErg > 0! 4801 ucSgIdx Parameter modification Knf_uiActuatorDirX while fuel/air ratio control is active or outside the operation modes “Burner Off” or “Fault” 4802 Zulässiger Kanal-Fahrbereich zu gering für Durchführung Max-Speed-Mes- sung...
  • Page 213 Assignment of internal fault 999 Description 6219 Point-approximation failed, invalid according point 6220 Punktindex Wirkkurve Evaluated-Correction-Setpoint-Writing failed (Ram-error) 6221 Punktindex Originalkurve invalid point-index 6222 Writing failed: Ram-error 6223 Writing failed: Ram-error Too many differences between curves  6224 Fehleranzahl (sliding counter, substract 1 per cycle) 6225 Statenummer undefined state of statemachine...
  • Page 214 Assignment of internal fault 999...
  • Page 216 Die Angaben in dieser Druckschrift gelten vorbehaltlich technischer Änderungen. LAMTEC Meß- und Regeltechnik LAMTEC Leipzig GmbH & Co. KG Presented by: für Feuerungen GmbH & Co. KG Wiesenstraße 6 Schlesierstraße 55 D-69190 Walldorf D-04299 Leipzig Telefon: +49 (0) 6227 6052-0 Telefon +49 (0) 341 863294-00 Telefax: +49 (0) 6227 6052-57 Telefax +49 (0) 341 863294-10...

  • Page 217: Recommended Spare Parts List

    HURST BOILER & WELDING CO., INC. RECOMMENDED SPARE PARTS LIST CUSTOMER: MOREX, INC. HBC JOB NO(S).: 1500479-480 NATIONAL BOARD NUMBER(S): 21033-34 DESCRIPTION: (2) 600 HP SCOTCH, 125 PSI WATER BURNER MANUFACTURER: OILON BURNER MODEL NUMBER: KP-600M BURNER SERIAL NUMBER: 9142005...
  • Page 219 BOILER PMI THERMOCOUPLE PRESS CONTR BOILER 115000045 5" STACK TEMP. GAUGE 150-750 BOILER 6" PRESS/TEMP GAUGE 60-260º 0-200 BOILER Notes: N/A = Not Applicable Hurst Boiler and Welding Co., Inc. CF = Consult Factory Prices subject to change without notice...
  • Page 221 Scotch Hot Water Front and Rear View (Optional LWCO) Gauge (Optional Low Fire Hold)
  • Page 223 Scotch Hot Water Side View (Optional Mod. Control) (Optional LWCO) Gauge 8, 9 Blowdown Valve...
  • Page 225 Primary LWCO Assy.

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