DUAL FUEL BURNERS · Operating Instructions For TD/TAD4 Dual Fuel Burner June 13 3 of 165 TD/TAD4 Manual Rev 4

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DUAL FUEL BURNERS

TD/TAD4

GENERAL INFORMATION

AND

OPERATING MANUAL

Operating Instructions For TD/TAD4 Dual Fuel Burner

June 13 2 of 165 TD/TAD4 Manual Rev 4

Revision Table

Rev No. Description Date By

1

2

3

4 Emergency stop information added - section 5.9

Exploded drawings revised – section 11

6.6.13 R.S



`TD/TAD` SERIES DUAL FUEL BURNERS

GENERAL INFORMATION AND OPERATING MANUAL

IMPORTANT

Throughout this publication Dunphy Combustion Limited are referred to as `The Company`.

The manual, which is supplied with every burner, should be read prior to the installation of the unit.

While giving information on the site work involved and on the burner commissioning procedure,

the content cannot include all of the data which may be necessary to achieve the design output of a

burner to a particular appliance because of the wide variety of heating and process plant for which

the burner is suitable precludes this.

The Company strongly advises that the commissioning of the burners is carried out by Dunphy

trained engineers and points out that it may be impossible to impart all the necessary information to

enable others to do so.

Under all circumstances the provisions of The Health and Safety at Work Act 1974 are the most

important consideration and if any doubts exist concerning the safe operation of the burner, The

Company should be contacted for advice. This provision also applies to the legislation of countries

to which the burners may be exported.

Where equipment, not of The Company`s supply, is used in conjunction with the burners, reference

should be made to specific instructions or regulations governing the installation and use of such

equipment.

The Company gratefully acknowledges the permission of component suppliers and others to

reproduce data sheets and technical information in this manual.

For reliable and efficient operation of the burner, it is essential that regular maintenance is carried

out in accordance with the instructions contained in the text of this manual. The fact that a burner

may be under warranty does not absolve the user from the responsibility for this and inadequate

maintenance may lead to claims, made under guarantees of materials or performance being denied

IF IN DOUBT - ASK!

Information contained in this manual is given without any responsibility on the part of the company

for the consequences of the actions of persons making use of such information.

Equipment is supplied strictly under the terms of The Company’s current `Conditions of Supply`

which are printed on the reverse of order acknowledgements and delivery notes.

Copies are available on request.



Contents 1 General Information ...................................................................................................................................... 7

1.1 General ............................................................................................................................................................ 7 1.2 Working parameters ................................................................................................................................... 7 1.3 Fuels ................................................................................................................................................................. 7

1.3.1 Fuel Tanks .............................................................................................................................................. 8 1.3.2 Filtration .................................................................................................................................................. 8 1.3.3 Ring Main Pumps .................................................................................................................................. 8 1.3.4 Pipe Runs ................................................................................................................................................ 8 1.3.5 Burner Connection ............................................................................................................................... 8 1.3.6 Burner Filtration ................................................................................................................................... 8 1.3.7 Pressure Regulation ............................................................................................................................ 8 1.3.8 Oil Line Connections ........................................................................................................................... 9

1.4 Burner construction .................................................................................................................................... 9 1.5 Burner details and power curve ........................................................................................................... 12 1.6 General arrangement details ................................................................................................................. 13

1.6.1 High low/modulating burners on gas, high low on oil ......................................................... 13 1.6.2 Electronic modulation burners (M RT) ....................................................................................... 14 1.6.3 TD10-415 Multi – Fuel Low Nox Burner General Arrangement ........................................ 16 1.6.4 TD420 Multi – Fuel Low Nox Burner General Arrangement............................................... 17 1.6.5 TAD420 Multi – Fuel Low Nox Burner General Arrangement ............................................ 18

2 Installation ........................................................................................................................................................ 19 2.1 Burner Mounting......................................................................................................................................... 19 2.2 Gas Valve mounting .................................................................................................................................. 20

2.2.1 Burner fitted with Unibloc ............................................................................................................... 20 2.2.2 Burner fitted with Siemens VGD40 gas valve ......................................................................... 22

2.3 Fuel oil installations .................................................................................................................................. 23 2.3.1 Pump Connections ............................................................................................................................. 23

2.4 Pump Priming .............................................................................................................................................. 23 2.5 Gas installation ........................................................................................................................................... 24 2.6 Electrical connections ............................................................................................................................... 24 2.7 Inverter Connection .................................................................................................................................. 24 2.8 Ventilation requirements ......................................................................................................................... 24

3 Combustion Head Settings ....................................................................................................................... 26 3.1 High / Low Burners ................................................................................................................................... 27 3.2 Modulating Burners ................................................................................................................................... 28 3.3 Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head ................................. 29 3.1 Modulating TD415-420 Burners Fitted With Low NOx Multi-Pipe Gas Head ....................... 31 3.2 Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil .......... 33 3.1 Modulating TD415-420 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil . 35 3.2 Modulating Burners Fitted With Bio - Gas Head ............................................................................ 37 3.3 Nozzle Adjustment .................................................................................................................................... 38

3.3.1 Gas Head ............................................................................................................................................... 38 3.3.2 Multipipe Gas Nozzle adjustment ................................................................................................ 38

4 Adjustments and Operating Principles ............................................................................................. 39 4.1 High/Low burners (HL) ............................................................................................................................ 39

4.1.1 High / Low Gas ................................................................................................................................... 39 4.1.2 High / Low Oil ...................................................................................................................................... 40

4.2 Pneumatic Modulating burners (M and M-sc) on Gas, High / Low on Oil ............................. 42 4.3 Electronic Modulation burners (M RT) ................................................................................................ 42

4.3.1 Oil Operating System Modulating Burners ART 114 and ART 1400 Nozzles ............... 43 4.3.2 ART114 Burner Gun .......................................................................................................................... 44 4.3.3 ART 1400 Burner Gun ...................................................................................................................... 44 4.3.4 Oil Operating System Modulating Burners ART 106 Nozzle .............................................. 46 4.3.5 Oil Operating System Modulating Burners Multi-Oil Nozzles ............................................ 48 4.3.6 Oil Operating System High/Low Burners Multi-Oil Nozzles................................................ 49 4.3.7 Oil Operating System Air / Steam Atomising .......................................................................... 50 4.3.8 Fuel Pumps and Motors ................................................................................................................... 51

5 Operation & User Interface ..................................................................................................................... 52 5.1 The Display / Keypad ............................................................................................................................... 52 5.2 Start -up Sequence ................................................................................................................................... 53



5.3 Modulation .................................................................................................................................................... 55 5.4 Normal mode ............................................................................................................................................... 55 5.5 Local mode ................................................................................................................................................... 55 5.6 Non-volatile lockout .................................................................................................................................. 55 5.7 Ratiotronic 6000 Inverter interface additional information ....................................................... 56 5.8 Post Purge Operation................................................................................................................................ 56 5.9 Emergency Stop ......................................................................................................................................... 57

6 Component Setup Parameters ............................................................................................................... 58 6.1 Ratiotronic 6000 ......................................................................................................................................... 58 6.2 Danfoss VLT FC 102 .................................................................................................................................. 64

6.2.1 RWF 40.000A97 Default Burner Settings ................................................................................. 66 7 Commissioning ................................................................................................................................................ 67

7.1 Basic settings .............................................................................................................................................. 67 7.2 Start Gas Heat Input ................................................................................................................................ 68 7.3 Pre-commissioning .................................................................................................................................... 69 7.4 Commissioning – High Low and Pneumatic Modulation burners - Firing on Gas .............. 70

7.4.1 Dry run ................................................................................................................................................... 70 7.4.2 Check for leaks through the automatic gas valve. ............................................................... 70 7.4.3 Check rotation of burner fan motor ............................................................................................ 70 7.4.4 Check for correct control sequence. ........................................................................................... 70 7.4.5 Firing the burner ................................................................................................................................ 71 7.4.6 Combustion values and results..................................................................................................... 71 7.4.7 Adjustment of Gas Proving Pressure Switch ........................................................................... 72

7.5 Oil Firing ........................................................................................................................................................ 72 7.5.1 Setting the Firing Rate, High / Low Oil Burners ..................................................................... 72

7.6 Electronic Modulating Burners .............................................................................................................. 75 7.6.1 Gas Butterfly Valve ........................................................................................................................... 75 7.6.2 Oil Metering Valve ............................................................................................................................. 75 7.6.3 Adjustment of air pressure proving switch .............................................................................. 75 7.6.4 Ratiotronic programming ................................................................................................................ 76 7.6.5 Setting the servo motors ................................................................................................................ 76 7.6.6 Burner Commissioning ..................................................................................................................... 76 7.6.7 Combustion values and results..................................................................................................... 76

8 Burner Maintenance Schedule ............................................................................................................... 77 8.1 Opening the Burner................................................................................................................................... 77 8.2 Minor Maintenance .................................................................................................................................... 78 8.3 Major Maintenance .................................................................................................................................... 78 8.4 Dismantling and Re-assembly of Burners ........................................................................................ 79

9 Faults and fault finding .............................................................................................................................. 81 9.1 Ratiotronic 6000/6006 ............................................................................................................................. 81

10 Useful Information ....................................................................................................................................... 82 11 Exploded Diagram & Spare Parts List ................................................................................................ 85

11.1 Modulating Oil Modulating Gas Setup ................................................................................................ 85 11.2 Modulating Oil Modulating Gas with DH2 Pump (TD420 Only) ................................................ 90 11.3 High Low Oil High Low Gas Setup (TD410 Only) ........................................................................... 94 11.3 Modulating Gas High Low Oil Setup (TD410 Only) ....................................................................... 99 11.4 Multi-Oil Multi-Gas Exploded Diagram ............................................................................................. 104 11.5 TD410 Low NOx Combustion Head Assembly ............................................................................... 109 11.6 TD415-420 Low NOx Combustion Head Assembly ..................................................................... 109 11.7 TD410 Combustion Head Assembly .................................................................................................. 110 11.8 TD415-420 Combustion Head Assembly ........................................................................................ 110 11.9 DN65 Unibloc ............................................................................................................................................. 111 11.10 DN80 Unibloc ......................................................................................................................................... 111 11.11 DN100 Unibloc ...................................................................................................................................... 111 11.12 VGD40.65 Assembly for Pneumatic Modulating and High Low Burners ......................... 112 11.13 VGD40.80 Assembly for Pneumatic Modulating and High Low Burners ......................... 112 11.14 VGD40.100 Assembly for Pneumatic Modulating and High Low Burners ....................... 113 11.15 VGD40.65 Assembly for Electronic Modulating Burners ....................................................... 113 11.16 VGD40.80 Assembly for Electronic Modulating Burners ....................................................... 114 11.17 VGD40.100 Assembly for Electronic Modulating Burners ..................................................... 114

12 Component Information .......................................................................................................................... 115 12.1 LFL1.333 Burner Control Box .............................................................................................................. 115



12.2 RWF 40 Burner temperature controller ........................................................................................... 123 12.3 Unibloc ......................................................................................................................................................... 128

12.3.1 Unibloc General Arrangements ................................................................................................... 128 12.3.2 65mm Ratiotronic Unibloc exploded diagram and parts list. .......................................... 130 12.3.3 65mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ...................... 131 12.3.4 80mm Ratiotronic Unibloc exploded diagrams and parts list ......................................... 133 12.3.5 80mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ...................... 134 12.3.6 100mm Ratiotronic Unibloc exploded diagrams and parts list ....................................... 136 12.3.7 100mm Ratiotronic Unibloc with pilot exploded diagrams and parts list ................... 137

12.4 Butterfly Gas Valve ................................................................................................................................. 139 12.4.1 General Arrangement ..................................................................................................................... 139 12.4.2 Exploded Diagram ........................................................................................................................... 140

12.5 Siemens VGD20 and VGD40 Gas Valve Blocks ............................................................................ 141 12.5.1 Siemens SKP actuators .................................................................................................................. 145

12.6 VPS 504 Valve Proving System .......................................................................................................... 151 12.7 Variotronic VT Oil Metering Valve ...................................................................................................... 154

12.7.1 General Description ......................................................................................................................... 154 12.7.2 Construction ....................................................................................................................................... 154 12.7.3 Valve Maintenance .......................................................................................................................... 154 12.7.4 Changing Seals ................................................................................................................................. 154 12.7.5 Adjustment of the valve ................................................................................................................ 155 12.7.6 Installation of the valve ................................................................................................................. 155 12.7.7 Valve Drive ......................................................................................................................................... 155 12.7.8 Exploded Diagram ........................................................................................................................... 156

12.8 DH Series Pump ....................................................................................................................................... 157 12.8.1 Pressure Regulation ........................................................................................................................ 158 12.8.2 Technical Data Summary .............................................................................................................. 159 12.8.3 Installation Operation Maintenance .......................................................................................... 160 12.8.4 Fault Finding ...................................................................................................................................... 161 12.8.5 Oil Flow Diagrams ............................................................................................................................ 162



During commissioning, all adjustments to the burner must be made in accordance with the boiler

manufacturer's instructions and these must include checking of flue gas temperature, average water

temperature and CO2 or CO concentration.

1 General Information

1.1 General

Burners must be checked at the time of delivery and any deficiencies or damage immediately

reported to the carrier or supplier. The company will make good any defects or replace missing

items strictly in accordance with their current conditions of supply.

The company has a policy of continuous development and therefore reserve the right to make

changes, without notice, in burner or other specifications.

Burners carrying the same model number may have major differences in their detailed

specification, such as draught tube lengths to suit the dimensions of a particular appliance, which

makes it impossible to give, in a single publication, precise information on the whole range of

applications. Data is readily available from the company and can be supplied on application.

Please give the burner serial number when requesting information.

All TD series burners are manufactured and tested to European Standards BS EN676: 2003 &

A2:2008 Automatic forced draught burners for gaseous fuels, Definitions, requirements, testing,

marking and EN 267 Forced draught oil burners – Definitions, requirements, testing, marking

If a burner is to be fitted to an existing boiler, maximum combustion efficiency can only be

achieved if all heat transfer surfaces are cleaned prior to the installation. Generally `TD` series

burners are not suitable for use in areas of high humidity or in explosive atmospheres, but special

units suitable for use in adverse situations can be manufactured to a customer's specific

requirements. Details of special units are available, on request, from the Dunphy sales department.

1.2 Working parameters

Temperature 0 to +50°C

Relative Humidity 60 - 90% non-condensing

Atmospheric Air Pressure – will generally be in the range of 950 to 1100mbar, but this will change

with altitude, if there are any queries please consult the Dunphy technical department.

1.3 Fuels

'TD / TAD' Series of burner must only be used with the fuels specified on the burner data plate and

in the case of gas, the pressure must not, under any circumstances, drop below the stated

minimum operating level.

The burner is also optimised for use with 35 sec diesel oil.

B100 Bio-diesel must not be used on a standard burner. When using B100, it must be specified at

time of order. Special pumps, valves and seals are used when burning B100.

It is essential that appliance and burner combinations are correctly matched.

If any doubt exists about the suitability of a particular combination the installer

must check with the manufacturers.



1.3.1 Fuel Tanks

Fuel storage tanks must be positioned to maintain a positive head to burners or ring main pumps,

regardless of the oil level in the tank.

Vertical and horizontal storage tanks should be mounted on concrete plinths in accordance with

local, national or any environmental standards that may apply.

The fuel lines and fuel filtration system must be sized to prevent any possibility of vacuum

occurring in the pump suction ports.

If a positive head of oil is not maintained, there is a possibility that cavitations will occur within the

fuel pump.

As a general guide, the fuel storage tanks must be mounted at least one meter above the ring main

fuel pumps which should be sited as close as possible to the tank discharge.

1.3.2 Filtration

Duplex fuel filtration is recommended to the ring main pumps, this will allow for maintenance

without shutdown of the ring main system, during normal operation of the plant.

1.3.3 Ring Main Pumps

The ring main pumps should be sized to give 100 to 150% over the burner pumps fuel

requirements.

Pumps must be fitted with an internal relief valve set at a maximum of 3 bar for pump protection.

Manual isolation valves should be fitted to the pump inlet and outlet pipework to allow for

maintenance. It is recommended that the valves have electric switch packs fitted to them so that

they can be interlocked with oil operation.

It is always preferable to use duplex pumping where practical, particularly on multi-burner

installations.

1.3.4 Pipe Runs

Pipework should be run in a manner that allows it to be self venting and, in sections that require

venting, a suitable vent or de-gassing section should be fitted.

Where overhead ring mains are to be installed particular care and attention should be taken that the

system can be adequately vented. Welded construction is preferable to screwed connections.

1.3.5 Burner Connection

Burner connections should be provided in the ring main pipework adjacent to the boiler and close

enough to allow the burner to be opened without the need to disconnect the flexible oil lines.

Note: - Manual isolation valves should not be fitted on the return lines.

1.3.6 Burner Filtration

Burner filtration will depend on the size of burners in question and the quality/grade of the fuel oil

to be used, but good quality fuel filters, preferably of the self-clean type are recommended.

1.3.7 Pressure Regulation

The Pressure regulating valve of the ring main must be of the low, or zero, hysteresis type and

capable of maintaining a stable ring main pressure through the minimum and maximum flow

conditions of the supply system irrespective of any change in flow volume or viscosity.

A number of suppliers manufacture valves suitable for this purpose and further details are available

from the Dunphy technical department.



1.3.8 Oil Line Connections

It is essential that the final connections between the main oil supply lines and the burner fuel pump

are made with flexible oil lines that are long enough to allow the burner to be swung open on its

hinges without having to be disconnected. Care should be taken to ensure that the flexible oil lines

do not become `kinked` as this will cause damage to the flexible and result in leakage.

1.4 Burner construction

Each ‘T’ series burner is constructed from 5 separate castings described as follows:

Hinge In common with all other body castings, the mounting casting is manufactured from aluminium

grade LM6 with the front face drilled to the dimensions given in section 1.5 of this manual suitable

for mounting studs. The rear face has two external lugs which form part of the burner hinge and is

drilled to accept the studs that are used to lock the burner closed.

Note: The fuel pipework enters this casting and it is essential that all joints and connections on the

combustion head are checked for security before the burner is hinged to the closed position. See the

maintenance section for details.

This casting houses the burner draught tube and combustion head along with the appropriate

ignition cables and flame detection equipment.

Fan case assembly

This consists of two aluminium castings with machined faces, bolted together and enclosing

the fan (which is sized to suit the particular burner model according to output and combustion

chamber resistance).

Integral with and inside the front half of the fan cases are the compressor blades; on the outside,

external lugs are attached with pins and thrust bearings to the burner mounting casting to form the

hinges.

The rear half is tapped to take the burner lifting eye and pads are used for the attachment of the

components on various models of the burner. The rear face is machined to match the air shutter

assembly, which is attached to it.

A differential air pressure switch, piped across the air inlet and pressure outlet of the combustion air

fan is mounted on the front section. Its function is to prevent the burner from firing if a supply of

combustion air is not available or to lock out the burner if the air supply is interrupted during

normal running.

Air shutter Combustion air is introduced through two concentric castings, one rotating about the other on a

PTFE bearing surface, regulating the combustion air supply through characterised slots to

accurately maintain the fuel air ratio. Close machining tolerances ensure almost zero leakage when

the damper is fully closed. The characterisation of the slots also ensures very high control of the air

supply at the important low fire end – typically 30 degrees of movement accounts for only 10% of

air throughput thus ensuring very high turndown capability.

The operation of the air shutter is activated by a reversible, mains voltage, synchronous motor (on

high/low burners) or a 240 (or 24V) motor with potentiometer control for fully modulating units.

Adjustable rigid linkage is used and the limits of travel are set by micro switches. Final adjustments

are made during commissioning.

On burners fitted with electronic modulation systems the air shutter and the fuel valves will all be

manufactured with individual drive motors controlled by the modulation system.



Figure 1

Figure 2

On burners which have air inlet silencers as standard a 0-10 scale is fitted to indicate the opening of

the air shutter (not the firing rate) and nylon support bearings ensure that the travel is as smooth as

possible.

Burner Motor

The burner (fan) motor is a continuously rated 2-pole unit with class 'F' insulation, sized according

to the application. The motor is mounted the inside of the inner shutter thus allowing 100% heat

recovery from the motor into the combustion air offering efficiency ratings greater than EFF1. This

also ensures inherently quiet operation from the burner.

Combustion Air Fan

Mounted directly onto the motor shaft and positioned within the fan case assembly, the fan supplies

combustion air via the compressor vanes and mounting casting to the combustion head.

Due to the 'T' burner requirement for extremely low vibration and noise levels the fans are

manufactured and balanced to the very highest standards (ISO 1940-2003).

All fans are colour coded according to size.

Combustion Head

The air for combustion passes from the burner fan at a pressure related to the resistance of the

boiler, down the draught tube to the combustion head. The latter is an assembly of components

which cause the gas to be discharged into the air flow in such a way that optimum mixing takes

place.

Many types of combustion head are available depending on appliance geometry, gas type, available

gas pressure, NOx level requirement etc…

Note: On any burner, an almost infinite combination of combustion head components may be used

to achieve optimum efficiency and a flame shape to suit a very wide range of heat-raising

appliances.

Burner Control Cabinet

Standard burners are supplied with a dust resistant damp-proof cabinet mounted on the side of the

burner. In many cases all the burner controls are fitted within the burner control cabinet (figure 1).

In more complicated installations, this cabinet would house a terminal strip (figure 2) which would

then interface to a control desk via flying leads.



Figure 3

Figure 4

Control desks are available in ‘wardrobe’ type style (figure 3) or ‘desk’ type style (figure 4). These

can vary in complexity and are able to house a whole host of burner/boiler controllers, water levels

controls, inverters, plc etc...

Air Inlet Silencer

Because of their design characteristics, 'T' series burners operate at very low noise levels, however,

further reduction of these levels can be made by fitting air inlet silencers which are designed to

cover the air shutter castings. The standard foam lined silencer typically offers sound levels in the

region of 80dBA. An optional ‘Snorkel’ type silencer is available which will reduce sound levels to

below 75dBA. Silencers can also be tailored to suit ducted air supplies, filters or additional acoustic

attenuation. For extremely sensitive installations, 'Acoustic Shrouds' which cover the entire burner

can be individually designed to suit most applications. Quotations are available on request.

Typical Acoustic Shroud Burner fitted with 'Snorkel' Silencer

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1.5 Burner details and power curve

*1 – Based on Nat. Gas C.V 10.4 kW/m3

*2 - Fitted with a Ratiotronic 6000 System

BURNER Firing Rate kW GAS

VOLUME (m3/HR)*1

FIRING MODE OPTIONS

Fan Motor KW

Pump Motor

kW Voltage Hz Ph

Running Current

Starting Current

TYPE MIN MAX MIN MAX

Mod Gas

High / Low Oil

High / Low

Electronic Modulation

*2

TD410Z 600 4500 58 433 7.5 2.2 380-420 50 3 23 Amp 48 Amp

TD415Z 800 5300 77 510

11.0 2.2 380-420 50 3 32 Amp 64 Amp

TD420Y 1250 6200 120 596

15.0 2.2 380-420 50 3 39 Amp 88 Amp

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1.6 General arrangement details

1.6.1 High low/modulating burners on gas, high low on oil

High Low and Pneumatic Modulation burners both use air/gas

ratio valves (details can be found in the component section of this

manual). They have built-in governors thus not requiring an

external governor for gas pressures up to 350mbar.

In this configuration the gas valve requires two signals from the

burner - the air pressure of the burner and furnace resistance of the

boiler. The furnace resistance is monitored with a stainless steel

piece of pipe which is projected into the furnace along the side of

the burner head. This will require an additional hole or notch in the

boiler mounting plate to accommodate – see mounting detail.

TD410 - 415 Burners with VGD40 Gas Valve



1.6.2 Electronic modulation burners (M RT)

Electronic modulation burners are fitted with on/off gas valves and

electronically controlled butterfly valves for the gas regulation. The

gas valve is generally a Unibloc (see component section for details)

however other valves can also be used depending on site details or

customer preference. An additional electronically controlled oil

metering valve is fitted for oil regulation – see principle of

operation section for more details.

TD410 - 415 Burners with Unibloc Gas Valve



TD420 Burners with Unibloc Gas Valve



1.6.3 TD10-415 Multi – Fuel Low Nox Burner General Arrangement



1.6.4 TD420 Multi – Fuel Low Nox Burner General Arrangement



1.6.5 TAD420 Multi – Fuel Low Nox Burner General Arrangement



2 Installation

2.1 Burner Mounting

Care must be taken when mounting the burner not to damage the mounting gasket. The furnace

pipe (where fitted) is generally positioned at 12 o’clock on the mounting flange and care must be

taken not to damage it during the mounting process.

Note: - Ensure that the burner mounting gasket is correctly fitted when fixing the burner to

the appliance. This gasket creates a gas-tight seal between the boiler and burner and also

insulates the burner mounting casting.

It is important to check that the burner draught tube projection into the combustion chamber

conforms to the appliance manufacturers instructions.

Non standard draught tube projections are available on request; - please consult the Dunphy sales

dept.

In general, for reverse flame boilers the draught tube projection into the combustion chamber

should be between 50 and 100mm. For other boilers the burner draught tube should finish flush or

slightly proud of any boiler refractory or insulation. Low NOx heads should be projected into the

furnace by at least 100 - 150mm.

If there is any doubt about the correct projection into the combustion chamber, the appliance

manufacturer must be consulted.



2.2 Gas Valve mounting

2.2.1 Burner fitted with Unibloc

The Unibloc gas valve is

a heavy item and will

require two persons to lift

it into position and secure

in place using bolts

provided.

The Unibloc is shipped

pre - connected. Please

consult electrical wiring

diagram for electrical

connections.

Governor shown is

supplied with every

burner using a Unibloc

gas valve and should be

installed according to

guidelines illustrated

below and approximately

10 pipe diameters

upstream of the gas valve.

Pipe work and isolating valve are supplied by others.

Important:

The installer must install a 90° turn type isolation ball valve next to or in close proximity to

the burner and capable of rapid operation.

The manual valve must be capable of operating at a pressure equal to 1.5 times the maximum

supply pressure and where possible must be orientated in such a way that when the valve closes the

handle must fall from the vertical to the horizontal. The valve must have mechanical end stops to

prevent the ball valve from going below the 0° point or above the 90° point.

The gas supply pipework

must be adequately

supported to prevent undue

stress on the burner casing or

the gas train components.

Gas supplies greater than

500mbar must be governed

down to a suitable gas

pressure below 500mbar

using a CE approved high

pressure gas governor. The

gas governor or should be

fitted as per manufactures

instructions, copies available

on request.

Typical Gas train installation

is shown on the right



VGD Gas Valve Orientation

Unibloc Orientation

Governor Orientation

Fit governor in accordance with manufactures instructions.



With the gas isolation valve next to the burner closed, a pressure test should be carried out on the

main gas supply pipe work and all connections checked with a suitable, non corrosive leak

detection fluid.

If the installation is supplied with a gas pressure above 1 bar (14.5p.s.i.g.) and contains plant with a

heat input of more than 2MW, local authorities will generally ask for the fitting of remotely

operable fire valves. The national or other standards in countries to which the burners may be

exported must be identified and met.

2.2.2 Burner fitted with Siemens VGD40 gas valve

The Siemens gas valve is a heavy item

and will require two persons to lift it into

position and secure in place using bolts

provided.

8mm blue and black PVC pipes plus

fitting are supplied with the burner. The

blue line must be connected between the

“Air” connection on the SKP75 actuator

and the air pulse line situated on the top

flat of the burner hinge section. The black

line must be connected between the

“Combustion Chamber” connection on the

SKP75 and the furnace line connection

protruding through the mounting flange of

the burner.

Important:

The installer must install a 90° turn type

isolation ball valve next to or in close proximity

to the burner and capable of rapid operation.

The manual valve must be capable of operating at

a pressure equal to 1.5 times the maximum supply

pressure and where possible must be orientated in

such a way that when the valve closes the handle

must fall from the vertical to the horizontal. The

valve must have mechanical end stops to prevent

the ball valve from going below the 0° point or

above the 90° point.

The gas supply pipework must be adequately

supported to prevent undue stress on the burner

casing or the gas train components.

The Siemens gas valve has a built-in governor and

is suitable for gas pressures up to 500mBar.

Gas supplies greater than 500mbar must be

governed down to a suitable gas pressure below

500mbar using a CE approved high pressure gas governor. The gas governor or should be fitted as

per manufactures instructions, copies available on request.



2.3 Fuel oil installations

Fuel oil installations must comply with the following British Standards or equivalent local, national

or international standards.

BS799 Oil burning equipment

BS5410 Code of practice for oil firing

BS2869 Fuel oils for non marine use

Installations must conform to local Bye-laws and regulations which should be identified by

application to the local planning authority.

2.3.1 Pump Connections

The burner is supplied with two flexible hose lines and is connected as shown in illustration below.

PUMP TYPE CONNECTION A CONNECTION B

DH1 Series

3/4" BSP

3/4" BSP

DH2 Series

1” BSP

1” BSP

2.4 Pump Priming

In order to ensure correct start-up for DH series oil pumps, the following guidelines should be

adhered to.

1. Ensure that the oil supply to the pump has been properly bled through and that no air is

present in the oil supply. The flexible oil lines should be fully flooded before connection to

the pump.

2. Check that all isolating valves are open and that the oil supply temperature and pressure are

correct.

3. Lubricate the pump by removing the pressure gauge plug and filling the pump with suitable

thin lubricating oil.

4. Check pumps rotation.

OIL RETURN FLEXIBLE

CONNECTION B

OIL RETURN FLEXIBLE

CONNECTION B

OIL RETURN FLEXIBLE

CONNECTION A

OIL RETURN FLEXIBLE

CONNECTION A



Warning:

Touching the electrical parts may be fatal – even after the equipment has been

disconnected from mains.

Also make sure that other voltage inputs have been disconnected, such as

load-sharing (linkage of DC intermediate circuit), as well as the motor

connection for kinetic back-up.

Before touching any electrical parts, wait at least: please consult the inverter

manual.

5. Turn pump slow until all air has been vented both from the pump itself and the burner

pipework, and the system is fully flooded.

6. The pump can now be put into operation.

2.5 Gas installation

Note: The national or other standards in countries to which the burner may be exported to must be

identified and adhered to.

2.6 Electrical connections

All electrical installation work must be carried out in accordance with the I.E.E. wiring regulations

17th Edition 2008, with further reference to the Health and Safety Executives `Memorandum of

Guidance on the Electricity at Work Regulations 1989 ( H.S.E. Booklet HS[R]25 )

Take note of the I.E.E. requirement for bonding main gas supply pipework to earth.

Connections to all terminals and the appliance should be made in accordance with the wiring

diagram supplied with each burner.

The final part of the electrical cable run must be made in flexible conduit, long enough to enable

the appliance door to be opened.

Ensure that the mains electrical supply to the burner is protected by a suitably sized fuse.

Connections to all terminals and the appliance should be made in accordance with the wiring

diagram supplied with each burner, using suitable fixed wiring installation (incorporating means of

disconnection) in accordance with local and national wiring regulations.

2.7 Inverter Connection

Burner motor connections can be found in dedicated aluminium enclosure situated on the side of

the burner control panel. Wiring diagram shows how to connect the inverter to this enclosure. The

earth leakage current from the frequency converter exceeds 3.5mA. To ensure excessive leakage

current conforms to EN/IEC 61800-5-1, an earth wire of at least 10mm2

or two separate earth

ground wires are used.

2.8 Ventilation requirements

In all cases, gas installation work must be carried out by approved members of

Gas Safe

All relevant standards of The British Standards Institute, IGEM Standard's

and the equivalent European Standards must be adhered to.



Provision must be made for an adequate supply of combustion and ventilating air to be available

when all access doors, fire doors and windows are closed. Air supply fans or flue dilution systems

must be interlocked to prevent operation of the burner(s) in the event of fan failure or shutdown.

To ensure an adequate supply of combustion air, the room in which the burner(s) are installed

should have permanent ventilation according to local or national standards.



3 Combustion Head Settings

On burners fitted with standard 'Z' and 'Y' type nose cones, the dimension 'A' between the end of

the burner nose cone and the front face of the flame plate, can be altered by releasing the three, M6

locking nuts inside the draught tube, and sliding the cone forwards / backwards, along its

adjustment slots until the required setting is obtained.

Important Notes:

Factory setting of gas flow is as shown on the following combustion head arrangement

drawings. Position of gas nozzles must be finalised at commissioning to suit the particular

boiler in which the burner is fitted.

When using low NOx heads, the projection must be at least 130-150mm past the boiler

refractory (into the furnace).



3.1 High / Low Burners



3.2 Modulating Burners



3.3 Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head





3.1 Modulating TD415-420 Burners Fitted With Low NOx Multi-Pipe Gas Head





3.2 Modulating TD410 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-Oil





3.1 Modulating TD415-420 Burners Fitted With Low NOx Multi-Pipe Gas Head & Multi-

Oil





3.2 Modulating Burners Fitted With Bio - Gas Head



3.3 Nozzle Adjustment

3.3.1 Gas Head

The Combustion head is attached to the gas inlet on the body. The gas flows through the gas annulus

and through the 4 holes in the gas nozzle.

The gas flow can be altered by adjusting the restrictor band, shown below. Undo the four M5 screws,

rotate the band to open or close the nozzle holes.

3.3.2 Multipipe Gas Nozzle adjustment

The Combustion head is attached to the gas inlet on the body. The gas flows through the 6 gas pipes and

through the holes in the gas nozzles.

The gas flow can be altered by rotating the nozzles to direct the gas either towards or away from the

centre of the burner.

The gas nozzles can also be adjusted along the multipipe head, this will either move the gas holes closer

or further away from the flameplate.

To carry out the above adjustments, loosen the 2x M4 grub screws on each nozzle securing the nozzle

to the pipe.



4 Adjustments and Operating Principles

4.1 High/Low burners (HL)

4.1.1 High / Low Gas

High low control is classed as the simplest form of control for a burner of this size. It relies on a

high/low thermostat monitoring either the temperature or pressure of an appliance which in turn via

the control box will drive the air damper servo between the high fire position and low fire position.

Gas regulation is performed by means of an air/gas ratio valve. The valve senses the amount of

combustion air available and regulates an internal gas governor to output sufficient gas to ensure

good combustion at both high and low firing rates. This also gives the feature of maintaining good

air gas ratio (therefore good efficiency) between high and low fire positions which wouldn’t be the

case on a standard 2 stage gas valve. When the burner is switched off the air damper will fully close

preventing any chimney buoyancy cooling of the appliance. Cam IV of the air servo motor is used

to set the ignition position of the air damper. Once the burner is lit and has stabilised the air damper

will move to either the low fire (CAM III) or high fire (CAM I) position depending on load

demand. Travel is adjusted by means of cam operated limit switches. The cam switch gears within

the motor can be disengaged by pushing the brass push button. Releasing the gears allows

adjustment of the air damper without connection to the drive unit. Adjustments of cams can be

made by hand or with the key which is housed within the motor cover.

Gas flow adjustments are made using the controls

‘V’ (for high fire adjustment) and ‘N’ (for low fire

adjustment) – see commissioning section for

details and gas valve manufacture details shown in

component section.

Cam I………... High Fire Gas

Cam II...............Air Damper Fully Closed

Cam III..............Low Fire Gas

Cam IV..... ........Ignition Position For Gas

Cam V...............High Fire Oil

Cam VI............. Low Fire Oil

Cam VII............V2 Oil



4.1.2 High / Low Oil

Atomisation of the fuel is by two separate nozzles, one for low fire and the second for high fire.

The oil supply to each nozzle passes through one of twin solenoid shut-off valves and the burner

output is determined by the size of nozzle and the pressure setting of the fuel pump regulator.

Normally, two nozzles of the same size will be used to give a total output equivalent to the

maximum continuous rating (MCR) of the appliance, and, At low fire, approximately 50% of

MCR.

Dissimilar nozzles can however be fitted to alter the low fire to high fire ratio. Nozzles of different

spray angle and patterns are used on various furnace configurations in order to give the appropriate

flame shape. The whole of the oil system is protected by a pump discharge valve ( PDV ) which is

fitted on the oil pressure outlet of the pump and which closes, isolating the oil system when the

burner is not running.

When the control box reaches the firing stage, the air damper drives to the low fire position

(CAM VI) and the ignition spark is switched on.

Both the PDV and first stage solenoid valve (V1) are energised simultaneously releasing oil

through the first stage nozzle, which is ignited by the spark from the ignition electrode.

The oil pressure should now be adjusted, by means of the pump pressure regulating screw, to give

approximately 50% of the MCR of the appliance and the air shutter adjusted to give optimum

combustion efficiency.

As the control box reaches the high fire stage, the air damper motor drives the air shutter to the

high fire position and sends a signal to the second stage oil valve (V2).

As a safety measure, the second stage oil valve is energised through an auxiliary switch in the air

damper motor (CAM VII). The logic of this arrangement is that the air damper must be in the `high

fire` position before the second stage solenoid can open, thus ensuring that an oil rich condition

cannot occur.

When a burner is switched from high to low fire, the closing speed of the solenoid will always be

faster than that of the air damper, so the combustion will again remain air-rich.

The oil pressure should now be adjusted, by means of the pump pressure regulating screw, to give

the full MCR of the appliance and the air shutter adjusted to give optimum combustion efficiency.

Nozzle throughputs are given in the table on the following page.

It is essential that, on completion, the burner is tried a number of times to ensure that changeover

between low and high fire is smooth and that the flame does not `lift off`.

LFN

HFN

V1

V2

GC

PGPDV

PUMP

P

S R

OIL SUPPLY

V1 Low Fire Valve NC

V2 High Fire Valve NC

PDV Pump Discharge Valve

PG Pressure Gauge

GC Gauge Cock

LFN Low Fire Nozzle

HFN High Fire Nozzle

P Pump Pressure

S Suction

R Return

OIL LINE SCHEMATIC FOR LIGHT OIL DUAL FUEL BURNERS

HIGH LOW WITH TWIN NOZZLES



HIGH/LOW BURNERS

NOZZLE PRESSURE/OIL THROUGHPUT TABLES

Rated Flow at

U.S. GALLONS PER HOUR

LITRES PER HOUR

100 P.S.I.

PRESSURE P.S.I.

PRESSURE BAR

G.P.H.

L/hr

125

150

175

200

250

300

350

10

12

14

18

20

25

1.00

3.78

1.12

1.22

1.32

1.41

1.58

1.73

1.87

4.56

5.00

5.39

6.11

6.44

7.20

1.10

4.16

1.23

1.35

1.46

1.56

1.74

1.91

2.06

5.01

5.49

5.93

6.73

7.09

7.93

1.20

4.54

1.34

1.47

1.59

1.70

1.89

2.08

2.25

5.47

5.99

6.47

7.34

7.73

8.64

1.25

4.73

1.40

1.53

1.65

1.77

1.98

2.16

2.34

5.70

6.24

6.74

7.64

8.05

9.00

1.35

5.11

1.51

1.65

1.79

1.91

2.13

2.34

2.53

6.15

6.74

7.28

8.26

8.71

9.73

1.50

5.68

1.68

1.84

1.98

2.12

2.37

2.60

2.80

6.84

7.49

8.09

9.17

9.67

10.8

1.65

6.25

1.84

2.02

2.18

2.33

2.61

2.86

3.09

7.52

8.24

8.90

10.1

10.6

11.9

1.75

6.62

1.96

2.14

2.31

2.47

2.77

3.03

3.27

7.98

8.74

9.44

10.7

11.3

12.6

2.00

7.60

2.24

2.45

2.65

2.83

3.16

3.46

3.74

9.12

9.99

10.8

12.2

12.9

14.4

2.25

8.50

2.52

2.76

2.98

3.18

3.56

3.89

4.20

10.3

11.2

12.1

13.8

14.6

16.3

2.50

9.50

2.80

3.06

3.31

3.54

3.95

4.33

4.67

11.4

12.5

13.5

15.3

16.1

18.0

3.00

11.4

3.35

3.67

3.97

4.24

4.74

5.20

5.61

13.7

15.0

16.2

18.3

19.3

21.6

3.50

13.0

3.91

4.29

4.63

4.95

5.54

6.06

6.55

16.0

17.5

18.9

21.4

22.6

25.2

4.00

15.0

4.47

4.90

5.29

5.66

6.32

6.93

7.48

18.2

20.0

21.6

24.5

25.8

28.9

4.50

17.0

5.03

5.51

5.95

6.36

7.12

7.79

8.42

20.5

22.5

24.3

27.5

29.0

32.4

5.00

19.0

5.59

6.12

6.61

7.07

7.91

8.66

9.35

22.8

25.0

27.0

30.6

32.3

36.0

5.50

21.0

6.15

6.74

7.28

7.78

8.69

9.53

10.3

25.1

27.5

29.7

33.6

35.4

39.6

6.00

23.0

6.71

7.35

7.94

8.49

9.49

10.4

11.3

27.3

30.0

32.4

36.7

38.7

43.3

6.50

25.0

7.27

7.96

8.60

9.19

10.3

11.3

12.2

29.6

32.5

35.1

39.7

41.9

46.8

7.00

26.5

7.83

8.57

9.26

9.90

11.1

12.1

13.1

31.9

35.0

37.7

42.8

45.1

50.5

7.50

28.0

8.39

9.19

9.92

10.6

11.9

13.0

14.0

34.2

37.4

40.4

45.9

48.4

54.1

8.00

30.0

8.94

9.80

10.6

11.3

12.6

13.9

15.0

36.5

39.9

43.1

48.9

51.6

57.6

9.00

34.0

10.1

11.0

11.9

12.7

14.2

15.6

16.8

41.0

44.9

48.5

55.0

58.0

64.8

10.00

38.0

11.2

12.2

13.2

14.1

15.8

17.3

18.7

45.6

49.9

53.9

61.1

64.4

72.0

11.00

42.0

12.3

13.5

14.6

15.6

17.4

19.1

20.6

50.1

54.9

59.3

67.3

70.9

79.3

12.00

45.0

13.4

14.7

15.9

17.0

19.0

20.8

22.4

54.7

59.9

64.7

73.4

77.4

86.5

13.00

49.0

14.5

15.9

17.2

18.4

20.6

22.5

24.3

59.3

64.9

70.1

79.5

83.8

93.7

14.00

53.0

15.7

17.1

18.5

19.8

22.1

24.2

26.2

63.8

69.9

75.5

85.6

90.2

101

15.00

57.0

16.8

18.4

19.8

21.2

23.2

26.0

28.1

68.4

74.9

80.9

91.7

96.7

108

16.00

61.0

17.9

19.6

21.2

22.6

25.3

27.7

29.9

72.9

79.9

86.3

97.8

103

115

17.00

64.0

19.0

20.8

22.5

24.0

26.9

29.4

31.8

77.5

84.9

91.7

104

110

123

18.00

68.0

20.1

22.0

23.8

25.5

28.5

31.2

33.7

82.0

89.9

97.1

110

116

130

20.00

76.0

22.4

24.5

26.5

28.3

31.6

34.6

37.4

91.2

99.9

108

122

129

144

22.00

83.0

24.6

26.9

29.1

31.1

34.8

38.1

41.2

100

110

119

135

142

159

24.00

91.0

26.8

29.4

31.7

33.9

37.9

41.6

44.9

109

120

129

147

155

173

26.00

98.0

29.1

31.8

34.4

36.8

41.1

45.0

48.6

119

130

140

159

168

187

28.00

106

31.3

34.3

37.0

39.6

44.3

48.5

52.4

128

140

151

171

180

202

One U.S. Gallon = 3.785 Litres

One U.S. Gallon = 0.83267 Imperial Gallons



4.2 Pneumatic Modulating burners (M and M-sc) on Gas, High / Low on Oil

M burners use the same air gas ratio valve as used on the high low burners

and therefore connections to the valve are the same and principle of

operation is also the same.

The control system however does differ in that the position of the air damper

can be done in incremental steps via a 3-stage switched input. This is

generally performed using a temperature or pressure controller, Dunphy use

an RWF40 controller to perform this function – see component section for

more details, however any suitable controller with a 3-stage output would

suffice. The RWF40 can either be mounted on the burner panel or remotely

somewhere within the customer panel. Air damper and gas valve adjustments

are the same as with the High Low burner above.

Principle of Operation for Oil is the same as in Section 3.1.2

Burners with extension M-sc are modulating burners with inverters fitted to control the speed of the

fan. This has the benefit of higher turn-down, improved combustion, much quieter operation and

energy saving. Its set point is derived from a potentiometer situated and mechanically connected to

the back of the air damper motor. As the control box drives the air damper motor up and down

according to the appliance load characteristics, the potentiometer sends a proportional signal to the

inverter which makes the fan go faster or slower depending on whether more or less air is required.

The inverter is setup in the factory and there is no need to make any adjustments.

4.3 Electronic Modulation burners (M RT)

ME burners are fitted with electronic control systems

which have direct control over the air damper and gas

butterfly valve using high precision digital servo motors.

The Air / Gas or Air / Oil ratio is defined by a profile

curve which is programmed into the controller during the

commissioning phase.

Ratiotronic 6000 series controllers are generally fitted to

these burners however Siemens LMV2.. series and

LMV5.. series controllers may also be offered as an

alternative.

ME burners are relatively complex products and it is

recommend that they are commissioned by qualified

Dunphy personnel.

Documentation on these controllers is too lengthy to

incorporate into this document and therefore is supplied as

a separate manual. Both manuals must be used in

conjunction with each other when commissioning and

operating the burner.



4.3.1 Oil Operating System Modulating Burners ART 114 and ART 1400 Nozzles

Atomisation of the oil is by means of a single nozzle which works on the spill-back principle. The

nozzle fits into a hydraulic nozzle line assembly that allows oil from the pump outlet to circulate

through the nozzle and back through the metering valve to the pump return when the burner is

ready to fire, N.C. solenoid valves 4 & 5 open allowing oil to flow through the nozzle. the return

path from the nozzle line flows through a metering valve and back to the return of the pump

through a safety shut off valve.

The oil volume is controlled by a metering valve 6, in the spill line restricting the amount of spilled

oil and therefore increasing the volume that passes through the nozzle for combustion.

Control of both the metering valve and the air shutter is achieved by means of independent servo

motors which are positioned by the electronic control system.

Key

1) Nozzle Line Assembly

2) Nozzle

3) Oil Pump (Dunphy)

4) Pump Discharge Valve - Normally Closed

5) Pump Discharge Valve - Normally Closed

6) Oil Metering Valve (Dunphy)

7) Pressure Gauge - 0-40 Bar

8) Gauge Clock

9) Non - Return Valve

10) Test Point

11) Flexible Oil Line (Supplied Loose)

12) Low Oil Pressure Switch (Optional)

13) High Oil Pressure Switch

14) Manual Isolation Valve with Switch Packs (when fitted), interlocked with oil select on

burner.



4.3.2 ART114 Burner Gun

To set the spring tension of the piston, the spring tension screw is set 20mm from the back chamber

as shown above. The piston stroke is setup using the piston limit screw. The screw is first fully

screwed in so that the piston cannot move; the screw is then moved out by 10mm to set the stroke.

The nozzle has a vent on the back chamber to allow the piston to move, DO NOT BLOCK THE

VENT.

4.3.3 ART 1400 Burner Gun

The ART1400 nozzle has a set spring tension and piston stroke; no adjustments can be made to the

operation of the burner gun.

The nozzle has a vent on the back chamber to allow the piston to move, DO NOT BLOCK THE

VENT.



6 10 14 18 21 24 MAX

40 - 7 11 18 26 37 49 150 2.5

50 - 9 14 22 33 47 61 180 2.85

60 - 11 17 27 40 58 74 200 3.15

70 16 22 30 43 56 72 86 210 3.2

80 18 24 34 48 64 83 98 230 3.2

90 20 27 37 54 72 94 110 254 3.2

100 22 30 42 60 80 105 122 270 3.2

112 24 33 46 67 90 118 137 290 3.2

125 27 36 52 76 103 135 153 320 3.3

140 31 42 59 86 117 152 172 380 3.35

160 35 48 67 98 132 175 196 430 3.5

180 40 54 76 112 150 195 220 460 3.6

200 44 60 86 126 170 220 245 550 4

225 48 67 96 143 192 250 276 600 4

275 58 80 118 175 240 310 337 700 4

300 62 88 130 195 270 350 368 750 4

330 67 96 145 220 300 395 405 800 4

360 73 106 160 240 335 - 440 870 4

400 79 117 180 266 375 - 490 900 4

450 89 133 198 296 420 - 557 960 4

500 98 148 220 333 467 - 612 1025 4

550 108 162 248 367 514 - 673 1100 4

625 124 184 281 417 584 - 765 1200 4

700 138 209 315 464 648 - 857 1300 4

ATOMIZER

NUMBERRECOMMENDED

MAXIMUM

TURN-DOWN RATIO

PUMP

OUTPUT

RETURN PRESSURES IN BAR

OUTPUTS IN KILOGRAMS/hr

CAPACITY TABLES FOR

TYPE ART114/1400 RETURN FLOW NOZZLES

Supply pressure - 30 bar Viscosity - 5cSt (35 secs Redwood) Maximum output with return closed.



4.3.4 Oil Operating System Modulating Burners ART 106 Nozzle

Atomisation of the oil is by means of a single nozzle which works on the spill-back principle.

From the schematic diagram below it can be seen that when the oil supply is admitted to the

nozzle by the two main oil valves, the flow can either pass through the nozzle into the furnace or

can return down the spill line to the pump return.

The control of the oil volume is achieved by a metering valve in the spill line restricting the amount

of `spilled` oil and therefore increasing the volume that passes through the nozzle for combustion.

Control of both the metering valve and the air shutter is achieved by means of a modulating

motor which is positioned by potentiometer according to the control signal.

On burner shutdown both the main safety shut off valves and the return safety shut off valves

close simultaneously to isolate the nozzle and reduce any possibility of oil spillage into the furnace.



CAPACITY TABLES FOR

TYPE ART 106 RETURN FLOW NOZZLES

Supply pressure - 20 bar Viscosity - 5 cSt ( 35 secs Redwood )

NOZZLE

NOZZLE OUTPUT Kg/hr

TURN-DOWN

NUMBER RETURN PRESSURE

@ 3 bar

CLOSED

RETURN

RATIO

1.25

1.9

5.3

2.8

1.5

2.15

6.4

3.0

1.75

2.6

7.5

2.9

2.0

3.05

8.5

2.8

2.25

3.4

9.6

2.8

2.5

3.8

10.8

2.8

2.75

4.1

11.0

2.7

3.0

4.2

13.0

3.1

3.25

4.75

14.0

2.9

3.5

5.0

15.0

3.0

4.0

5.7

17.0

3.0

4.5

6.5

19.5

3.0

5.0

7.3

22.0

3.0

5.5

7.7

24.0

3.1

6.0

8.5

26.0

3.1

6.5

9.0

28.0

3.1

7.0

9.8

30.0

3.1

7.5

10.2

32.5

3.2

8.0

11.0

35.0

3.2

8.5

11.5

37.0

3.2

9.0

12.2

39.5

3.2

10.0

13.5

44.0

3.3

11.0

15.2

48.0

3.2

12.0

17.0

53.0

3.2

14.0

18.7

62.0

3.3

16.0

21.5

71.0

3.3

18.0

23.8

80.0

3.4

20.0

26.5

88.0

3.3

Note:- Turn-down ratio will increase with supply pressures

OIL SUPPLY

OIL RETURN

ART 106

SPILL-BACK NOZZLE BLOCKART 106

SPILL-BACK OIL NOZZLE

ART 106 SPILL-BACK NOZZLE BLOCK AND NOZZLE



4.3.5 Oil Operating System Modulating Burners Multi-Oil Nozzles

Atomisation of the oil is by means of three nozzles which work on the spill-back principle. The

nozzle fits into the hydraulic nozzle line assemblies that allow oil from the pump outlet to circulate

through the nozzles and back through the metering valves to the pump return when the burner is

ready to fire, two PDV N/C solenoid valves open allowing oil to flow through the nozzles. The

return path from the centre nozzle flows through metering valve MV1, while the three outer nozzle

flows through MV2, they then join a common oil line, passing through two N/C safety shut off

valves, and back to the return of the pump.

The oil volume is controlled by the metering valves (MV1 and MV2) in the spill line restricting the

amount of spilled oil and therefore increasing the volume that passes through the nozzle for

combustion.

Control of both metering valves and the air shutter is achieved by means of independent servo

motors which are positioned by the electronic control system.



4.3.6 Oil Operating System High/Low Burners Multi-Oil Nozzles

Atomisation of the oil is by mean of three outer nozzles and one central nozzle. The pump pressure

is set at 25 Bar, the two pressure regulators controlling the pressure to all four nozzles are set at 10

Bar. On Low fire V1, V2 and V3 are open, V4 is closed. This allows oil to pass through all four

nozzles at a pressure of 10 Bar. On High fire, V1,V2, V3 and V4 are opened, oil at 10 Bar flows

through the centre nozzle, oil flows through the three outer nozzles at 25 Bar through V4 bypassing

the pressure regulator through V3.



4.3.7 Oil Operating System Air / Steam Atomising

The ‘TA’ principle of operation is that oil, carrying both heat and hydraulic energy, enters a mixing

chamber in the nozzle where it is mixed with the streams of the atomising fluid (compressed air or

steam), carrying kinetic energy and in the case of steam, heat energy.

The combination of forces resulting from the directional differences between the oil flow, steam

flow and the kinetic and heat energy forces cause an emulsification process to take place.

The oil/steam or oil/air mixture then impinges on the nozzle pintle plate which gives secondary

atomisation, and finally passes out of the nozzle orifice which imparts a swirling motion into the

finely atomised spray. The emerging angle of the spray can vary according to the type of nozzle

fitted.

The oil supply from the pump passes through the pump discharge valve, the pre-heater the metering

valve and the nozzle line and goes back to the pump return via the V1 main oil valve and a non-

return valve. When the burner is switched on, the oil pre-heater (When fitted) is energised and the

oil temperature is raised to the required level. When the oil reaches the required temperature the

burner motor/pump is started and the oil is allowed to circulate through the burner pipework until

the correct temperature is attained throughout the system.

The check stat then sends a signal to the control box which starts the firing cycle by opening the air

damper to the high fire position. When the control box reaches the firing stage, the air damper

drives to low fire position and the ignition spark is switched on.

Both V1 normally open and V1N normally closed nozzle line solenoids are energised together

releasing oil through the nozzle, and the atomising medium solenoid (PV) opens to allow air or

steam into the nozzle mixing chamber.

The resulting mixture is ignited by the spark from the ignition electrode or by a pilot gas ignition

system.

The main oil pressure is set, by means of the pump pressure regulating screw and the atomising oil

pressure adjusted at the metering valve to give the correct low and high fire oil throughputs. The

atomising medium pressure must be adjusted at the pressure regulator (RG) in conjunction with the

oil pressure to ensure smooth light up and optimum combustion throughout the firing range.

The air shutter is adjusted to give optimum combustion efficiency throughout the firing range.



4.3.8 Fuel Pumps and Motors

All `TD` series burners are supplied with a separate, directly coupled fuel pump and drive motor.

Details of the various sizes of pumps and motors are given in the table below.

BURNER TYPE

PUMP TYPE

MOTOR SIZE

(kW)

RPM

DRIVE

COUPLING

OIL LINE

CONNECTIONS

TD410ZHL

DH1-1-30

1.1

2800

Fig 71

3/4" BSP

TD410ZM

DH1-1-30

1.1 or 2.2

2800

Fig 71

3/4" BSP

TD415YM

DH1-2-30

2.2

2800

Fig 71

3/4" BSP

TD420YM

DH2-1-30

3.0

2800

Fig 71

1" BSP



5 Operation & User Interface

5.1 The Display / Keypad

The display is a 2 line, 20 characters per line, dot matrix vacuum fluorescent type allowing the use

of plain text messages for display parameters. The keypad is a membrane construction with tactile

keys to give a positive feedback of the actuation.

Key Function

EK Selects Engineers Key mode.

LOW FIRE Pressing this key will force the burner to Low fire until the key is pressed

again to release the burner to modulate.

FUEL SELECT Changes Fuel/Profile. If the fuel is changed when the burner is firing, the

burner will go off then restart firing the new fuel selection.

BURNER O-I Sets the burner On or Off and enables changes between normal and local

operation. Note: Terminal PE9 must be ON for this switch to start the burner.

MUTE / RESET Press this key to mute (open) the alarm relays, and then hold the key down

for approximately three seconds to reset the cleared faults.

AUTO / HAND Selects auto or manual burner modulation. In manual mode the UP/DOWN

keys are used to alter the fire rate.

DATA Selects different data types on the display window.

COM Changes operation to commission mode via a pass-code.

The UP/DOWN keys are used to adjust the fire rate in

manual modulation mode.

In commission mode, they

are used for data value

selection.

The SCROLL keys are used to

view boiler and burner status

data during normal running conditions.

In commission mode, these keys select option parameters,

which are adjusted by the

UP/DOWN keys.

Alternate key functions

when in commission

mode.



5.2 Start -up Sequence

When a fuel selection is made and the ‘burner select’ signal is given to start up the burner, the

controller performs the sequence described below. If a gas profile is selected and the safety valve

proving function is selected, the controller will perform safety valve pressure proving concurrently

with the start-up sequence.

State

no.

State name Description

0.

Non-volatile

lockout

All fuel valve outputs are OFF and the Alarm output is ON until

muted. The burner is held in this state until all faults are

removed.

1.

Burner off

The burner is checked to make sure that it has switched off

completely. Testing includes - main fuel safety valves closed, no

flame signal and no air pressure’ signal. The controller will

remain in this state until there is a call for heat from the PID

system.

2. Wait for purge The controller waits for both a burner select (PE9 ON) and a

fuel/air profile to be selected. Progression to stage 3 or 5 maybe

held off by external influences, e.g. Digital Communications

control or digital input controlled by an external circuit.

3. Open fuel valve If gas firing and safety valve proving are selected, the gas valve

servo motor is moved ‘open’ for five seconds to allow any gas

in the test section to be vented easily during the proving

sequence.

4. Hold fuel valve The fuel motor is held in position until step 1 of the safety valve

proving sequence (open main valve 2, or vent valve) is

completed.

5. Prove closed

positions

If gas is selected, the gas valve proving sequence begins. The

fuel and air motors are moved to closed position until they stop.

The final positions are compared with the closed positions

stored in memory when the profile is commissioned.

6. Prove air

pressure

The burner motor output is set ON and air pressure prove time

(t1) is initiated. The selected motors are moved ‘open’ towards

the purge position. If the ‘fan start early’ option parameter has

been set then the motors will not move until the option time has

expired.

7. Prove purge

positions

When the air pressure prove time has elapsed, the air pressure

switch must give a ‘pressure’ signal or the controller will

lockout the burner and move to stage 0. If primary air is

selected, then both primary and secondary air pressure signals

must be ON to prove air pressure. The selected motors are

driven ‘open’ until they reach their commissioned purge

position.



State

no.


8. Pre-purge Once the servo motors are at their purge positions the controller

starts the pre-purge (t2) timer.

9. Move to ignition

positions

When t2 has elapsed, the fuel and the air motors are moved to

the ignition position for the selected profile. The controller will

wait at the ignition positions while the gas valve proving

sequence finishes before progressing to stage 10

10. Pre-ignition Once the fuel and air motors are at their ignition positions, the

ignition transformer output is energized and pre-ignition time

(t3) is starts.

11. Pilot ignition

Once t3 has elapsed the ignition transformer remains on, first

main valve if required for pilot flame gas, and pilot valve

outputs are energised and the first safety time (t4) is started.

If firing on oil and ignition selected to be with both pilot and

main valve, use timing in the start-up sequence table for main

valve 1.

If firing on oil and ignition with main valve is not selected the

pilot ignition will occur with only the pilot valve, use timing in

the start-up sequence table for main valve 2.

12. Pilot ignition

interval

When t4 is complete, a flame must be detected or the controller

will lockout the burner and move to stage 0. The ignition

transformer may optionally be on or off (See option parameter

14.6).

13.

Main ignition Once the pilot interval time (t5) has elapsed, the second (and

first if not already open) main valve output(s) for gas, or main

oil valve output for oil is energized and the second safety time

(t6) is started.

If firing on oil and ignition with main valve was selected the

main oil valve will have already opened for pilot ignition. The

ignition transformer may optionally be on or off (See option

parameter 14.6). A flame and air pressure signal must be

detected or the controller will lockout the burner and move to

stage 0.

14. Wait for Main

flame established

When t6 has expired, the pilot valve output is turned off. If

permanent pilot is selected and the burner is firing on gas, then

the pilot will remain open with the main valves.

Main flame interval time (t7) is started. A flame and air pressure

signal must be detected or the controller will lockout the burner

and move to stage 0.

15. Moving to low

fire

When t7 has elapsed, the flame is considered established and the

fuel and air motors are moved from their ignition positions to

their low fire positions and held at those positions for the

duration of the Low Fire Hold Time (t8). A flame and air

pressure signal must be detected or the controller will lockout

the burner and move to stage 0.



State

no.


16. Modulation When t8 has elapsed the fuel and air motors are modulated

according to the demand placed on the burner. If the fuel

selection is changed or the ‘burner on’ signal (PE9) is removed,

the main valve output(s) are turned off. A flame and air

pressure signal must be detected or the controller will lockout

the burner and move to stage 0.

17. Move to post-

purge

If Post Purge is not selected then the controller returns to state 1

to wait for another start-up.

If Post Purge has been selected then the fuel servo motor is

moved to its closed position, and the selected air motor(s) are

moved to their post purge position(s).

18. Post-purge When the air drive(s) have reached their post purge positions

then the Post Purge Time (t9) is started. When t9 has elapsed,

the burner motor is turned off and the controller returns to state

1 to wait for another start-up.

5.3 Modulation

During stage 16 (modulation), the controller will position the fuel and air motors within the

programmed profile appropriate to the requirement for heat. The controller has 2 modes of

operation using the standard RATIOTRONIC modulation function, Normal and Local. The mode

of operation is set via the keypad by pushing the “Burner ON/OFF” key and selecting the mode.

Using the programmable block function (option) within the controller it is possible for the

modulation control to be generated with customised options, these are not covered in the standard

manual.

5.4 Normal mode

In Normal mode, the modulation rate is determined by the internal PID control settings, Manual

modulation from the keypad, or by one of the following remote influences:

Auxiliary modulation input,

Digital set point selection

Serial communications – Comview or Lead/Lag.

5.5 Local mode

In Local mode, the modulation rate is determined by either the internal PID settings or Manual

modulation via the UP/DOWN keys. External modulation inputs and set point selection inputs are

ignored.

When “Local1” is displayed the burner is running using the Set point 1 PID settings.

When “Local2” is displayed the burner is running using the Set point 2 PID settings.

5.6 Non-volatile lockout

Non-Volatile lockouts cannot be cleared without operator intervention and are remembered in the

event of power being removed from the controller.

A non-volatile lockout will occur under the following conditions:



If any step of the gas proving sequence fails

In stages 1-9 (inclusive) if a flame is detected

In stages 11-16 (inclusive) if a flame is not detected

In stage 4 if the air pressure switch goes high (air pressure present)

In stages 7-18 (inclusive) if the air pressure switch goes low (air pressure not present)

In stages 5, 7 and 8, stages 10-16 (inclusive) and stage 18 if a motor is not in the correct

position

In any stage, if an internal or external fault not previously mentioned occurs which may

affect the safe operation of the burner

5.7 Ratiotronic 6000 Inverter interface additional information

The Ratiotronic 6000 may have an optional daughter board within the main enclosure to allow

control of 1 or 2 inverter drives (daughter board dependent). Optionally the daughter board is also

available to allow feedback to be taken from directly from encoders measuring the speed of the

relevant motor, fan or pump shaft. There is also an option to allow the speed of an additional rotary

device to be monitored as an encoder input.

When not configured to control an inverter, the 4-20mA outputs may be configured to transmit

system variables as current outputs.

There are special wiring requirements for inverter feedback.

5.8 Post Purge Operation

If a post combustion purge is selected (with option parameter 7.9), a normal shutdown post purge

will be performed at low fire. The drives will move to the low fire position (if not already there)

and the post-purge time will then start. If the burner has turned off because the fuel profile selection

has been removed (i.e. set to NONE), no post-purge will be performed.

If the burner locks out at or after ignition, and a post-purge time has been entered, the controller

will also attempt a post purge. For a flame failure fault, the controller will attempt to post purge at

high fire. For all other faults, the drives will stay at the positions they were in when the lockout

occurred. In both cases, the post-purge time starts at the moment the lockout occurs – the controller

does not wait for drives to position before starting the post-purge time.



5.9 Emergency Stop

The emergency stop or e-stop is a safety mechanism used to shut off the burner in an emergency

situation in which it cannot be shut down in the usual manner. Unlike a normal shut-down

switch/procedure, which shuts down the burner in an orderly fashion and turns it off without

damaging it, an e-stop is designed and configured to a) completely abort the operation at all costs

and b) be operable in a manner that is quick, simple (so that even a panicking user with

impaired executive function can operate it), and, usually, c) be obvious even to an untrained

operator or a bystander. The e-stop features a removable barrier to provide protection against

accidental activation.

http://en.wikipedia.org/wiki/Safety

http://en.wikipedia.org/wiki/Panic

http://en.wikipedia.org/wiki/Executive_function



6 Component Setup Parameters

Before the commissioning process of the burner can take place, there are certain components like

the Ratiotronic 6000, inverter (when fitted), etc, which will need to be setup. The burner should be

factory set; however, if the parameters have been erased for whatever reason, then this section can

be used as a starting point. Please note that a fuel / air profile will not have been setup. Please also

note that this parameter set should be used in conjunction with the manual.

6.1 Ratiotronic 6000

Option Value Description Comments

0.1 xxx Site passcode last 3 digits of burner serial number

0.2 0 Serial communications control address

0.3 0 Reset hours run

0.5 0 Language Select

0.7 1 IsoComsAddress

0.8 2 IsoComsSetting

1.0 5 Power up option 5=ignore alarms for 5 seconds at

power up

1.1 1 Keyboard auto/manual enable

1.2 0 Fault mute input enable

1.3 0 External profile select enable

1.4 0 Gas valve proof of closure select

1.5 0 Oil valve proof of closure

1.6 0 Second airflow switch (primary air) enable

1.7 0 Safety time configuration set

1.8 0 Force Mode Input

2.0 0 Drive 0 name not used

2.1 2 Drive 1 name gas servo motor

2.2 3 Drive 2 name oil servo motor

2.3 10 Drive 3 name air servo motor

2.4 11 Drive 4 name VSD drive

2.5 0 Drive 5 name

2.6 0 Drive 6 name

2.7 0 Drive 7 name

2.8 0 Drive 8 name

2.9 0 Drive 9 name

3.0 0 Drive 0 serial number not used

3.1 xxxx Drive 1 serial number - Gas Servo 1st 4 Digits of Ser No

3.2 xxxx Drive 2 serial number - Oil Servo 1st 4 Digits of Ser No

3.3 xxxx Drive 3 serial number - Air Servo 1st 4 Digits of Ser No

Found on side of servo motor

3.4 VSD1 Drive 4 serial number

3.5 0 Drive 5 serial number





4.0 0 Drive 0 profile assignment not used

4.1 1 Drive 1 profile assignment profile 1

4.2 2 Drive 2 profile assignment profile 2

4.3 3 Drive 3 profile assignment profiles 1 + 2 = 3

4.4 3 Drive 4 profile assignment profiles 1 + 2 = 3



4.5 0 Drive 5 profile assignment





5.0 0 Drive 0 rotation 0 = anti-clockwise / 1 = clockwise










6.1 1 Fuel train for profile 1 gas

6.2 1 Fuel train for profile 2 oil

6.3 0 Fuel train for profile 3

6.4 0 Fuel train for profile 4

7.0 0 Fan on early time

7.1 15 Air Proving time

7.2 30 Pre-purge time Do not reduce this timing

7.3 1 Pre-ignition time Do not extend this timing

7.4 3 Pilot ignition time Do not extend this timing

7.5 3 Pilot hold time Do not extend this timing

7.6 3 Main ignition time Do not extend this timing

7.7 3 Ignition hold time Do not extend this timing

7.8 5 Low fire hold time Do not extend this timing

7.9 30 Post purge time Do not reduce this timing

8.0 0 Ignition spark output check

8.1 1 Flame failure response time

8.2 0 Extend false flame response time

9.0 0 Inverter control accuracy 0 = low / 1 = high

9.1 1 Inverter error tolerance 0 = low / 1 = high

9.2 100 Inverter closed loop gain

9.3 30 Inverter stop time

9.4 30 Inverter acceleration time

9.5 0 VSD1 speed encoder scaler

9.6 0 VSD2 speed encoder scaler

9.7 0 Low speed cup limit

9.8 0 Oil warning speed

10.0 0 Gas pressure sensor select 1 – valve proving via sensor, 0 – valve proving via pressure switches

10.1 0 Gas pressure sensor span 10.2 70 Gas pressure nominal Parameters 10.2, 10.5 and 10.6 will

give a valve proving time of approx 40secs. This is an optimised set of figures – do not alter

10.3 0 Gas pressure low limit 10.4 0 Gas pressure high limit

10.5 1 Test volume



10.6 7.5 Maximum permissible leakage rate

10.7 0 Vent valve select

10.8 1 Valve proving select 1 – VPS enabled, DO NOT DISABLE

10.9 3 VPS Power Time

12.0 0 Photocell / IR flame detection select

12.1 0 Pilot flame threshold photocell

12.2 0 Main flame threshold photocell

12.3 0 Centre frequency photocell

12.4 0 Frequency pass ban photocell

13.0 x UV/Ionisation flame detection 1=non-shuttered/2=shuttered 13.1 x Pilot flame threshold non-shuttered = 20, shuttered = 10

13.2 20 Main flame threshold

14.0 6 Primary fault relay

14.1 0 Limit relay

14.2 0 Oxygen + fuel temperature limit relay

14.3 0 Permanent gas pilot select

14.4 1 Pilot with/without main valve select 0 = without / 1 = with

14.5 1 Direct ignition on oil

14.6 0 Spark termination

14.7 1 Oil pump relay function 1 = light oil / 2 = heavy oil

14.8 0 Extended oil pilot

15.0 2 Modulation input sensor type 2 = 4-20mA

15.1 x Modulation input decimal places 0 = temp / 1 = pressure

15.2 0 Modulation input zero value

15.3 xx Modulation input span value default: temp = 150, pressure = 16.0

15.4 x Set-point display units 1 = bar / 3 = deg c

15.5 0 Boiler high safety limit

15.6 20 Modulation time

15.7 0 Bumpless transfer

15.8 1 Low fire before off 0 = no / 1 = yes

16.1 0 Go back to pilot

16.2 0 Allow profile swap online

16.3 011 HV input 12 alarm/lockout function Boiler high limit stat, on PE7

16.4 012 HV input 13 alarm/lockout function Fan trip, on PE8 16.5 xx HV input 12 display message 11 – high temp, 13 – high pressure,

on PE7

16.6 17 HV input 13 display message Fan interlock, on PE8

17.1 0 Relay 1 output function (display unit) PR1,PR2,PR3



17.4 20 Relay 4 output function (controller) PD6,PD7,PD8



17.7 26 Relay 7 output function (26 = VSD1 start circuit) PZ17-PZ18

17.8 0 Relay 8 output function PZ15-PZ16

18.1 0 LV input 1 function PB9-PB10




18.5 22 LV input 5 function Low Gas Pressure PB14-PB15

18.6 21 LV input 6 function High Gas Pressure PB14-PB16






19.1 0 LV input 1 message PB9-PB10




19.5 5 LV input 5 message Low Gas PB14-PB15

19.6 4 LV input 6 message High Gas PB14-PB16




20.0 0 Set-point select input 1-7 or 12-13

20.1 0 Boiler shutdown input 1-7 or 12-13

20.2 0 Low fire hold input 1-7 or 12-13

20.3 0 Oxygen trim disable input 1-7 or 12-13

20.4 0 Ignition wait input 1-7 or 12-13

20.5 0 Purge hold input 1-7 or 12-13

20.6 0 Purge time start input 1-7 or 12-13

20.7 0 Analogue input 5 option aux mod input

20.8 0 Lead boiler select 1-7 or 12-13

21.0 0 Set-point 1 enable

21.1 x Set-point 1 control value default: temp = 80, pressure = 8.0

21.2 0.5 Set-point 1 proportional value default: temp = 1, pressure = 0.5

21.3 1 Set-point 1 integral time

21.4 0 Set-point 1 derivative time

21.5 2 Set-point 1 control limit type Deviation 21.6 0.5 Set-point 1 low limit control value default: temp = 10, pressure = 0.5

Burner On 0.5 below SP

21.7 0.5 Set-point 1 high limit control value default: temp = 10, pressure = 0.5 Burner Off 0.5 above SP

21.8 0 Remote set-point 1 zero (4mA) value

21.9 0 Remote set-point 1 span (20mA) value

22.0 0 Set-point 2 enable

22.1 0 Set-point 2 control value

22.2 0 Set-point 2 proportional value

22.3 0 Set-point 2 integral time

22.4 0 Set-point 2 derivative time

22.5 0 Set-point 2 control limit type

22.6 0 Set-point 2 low limit control value

22.7 0 Set-point 2 high limit control value

22.8 0 Mod Max Enable Input

22.9 0 Mod Max Value

23.0 0 Warming enable

23.1 0 Warming limit

23.2 0 Warming time

24.0 0 Number of sequence lag boilers enables into sequencing

24.1 0 1st lag boiler address

24.2 0 2nd lag boiler address

24.3 0 3rd lag boiler address

24.5 0 Lead assign type

24.6 0 Lag on rate



24.7 0 Lag on delay

24.8 0 Lag off rate

24.9 0 Lag off delay

29.0 0 Analogue output 1 function VSD1 overrides if selected

29.1 0 Analogue output 1 zero (4mA) value

29.2 0 Analogue output 1 span (20mA) value

29.3 0 Analogue output 2 function VSD2 overrides if selected



29.6 0 Analogue output 3 function



30.0 0 Oxygen probe interface serial number

30.1 0 Oxygen probe calibration offset value

30.2 0 Oxygen probe calibration gain value

30.3 0 Oxygen probe calibration gas concentration

30.4 0 Flue & inlet temp sensor units

30.5 0 Oxygen input function

30.6 0 Oxygen probe calibrate enable

30.7 0 Boiler transport delay

30.8 0 Reset oxygen trim profile

30.9 0 Automatic trim commissioning

31.0 0 Limit modulation range 31.1-31.4 0 Trim type for profiles

32.0 0 Trim limit default 32.1-32.4 0 Trim limits

33.1-33.4 0 Trim integral gain

34.0 0 Trim proportional gain default 34.1-34.4 0 Trim proportional gain

35.0 0 Inlet temp sensor serial number 35.1-35.4 0

Hydrocarbon ratios for each fuel respectively

35.5-35.8 0

Calorific values of fuels / profiles 1-4 respectively

35.9 0 Boiler radiated heat loss

36.0 0 Flue temperature alarm select 36.1-36.4 0 Flue temperature low alarm value

37.1-37.4 0 Flue temperature high alarm value

38.0 0 Oxygen alarm select 38.1-38.4 0 Oxygen low alarm value at low fire

39.1-39.4 0 Oxygen low alarm value at high fire

40.1-40.4 0 Oxygen high alarm at low fire

41.1-41.3 0 Oxygen high alarm at high fire

42.0 0 Second oxygen probe select



42.1 0 Second oxygen probe calibration offset

42.2 0 Second oxygen probe calibration gain

42.4 0 Maximum oxygen variation

42.5 0 Maximum flue temp variation

42.6 0 Second oxygen probe calibration enable

44.0 0 Set real time clock

44.1 0 Set year

44.2 0 Set month

44.3 0 Set day of month

44.4 0 Set day of week

44.5 0 Set hours

44.6 0 Set minutes

44.7 0 Set seconds

44.9 0 Clear fault history

45.0 0 Erase/Restore enable

45.1 0 Erase command

45.2 0 Restore command



6.2 Danfoss VLT FC 102

PNU NAME FACTORY DEFAULT DCL SETTING

0-20 DISPLAY LINE 1.1 REF % ANALOG INPUT 53

0-21 DISPLAY LINE 1.2 MOTOR AMPS

0-22 DISPLAY LINE 1.2 POWER KW

0-23 DISPLAY LINE 2 FREQUENCY HZ

0-24 DISPLAY LINE 3 KW/H COUNTER SPEED RPM

0-40 LCP HAND START ENABLE DISABLE

0-41 LCP STOP ENABLE DISABLE

0-42 LCP AUTO START ENABLE DISABLE

0-43 LCP RESET ENABLE

1-00 CONFIG MODE OPEN LOOP

1-03 VT CHARACTER AEO FUNCTION

1-20 MOTOR POWER xxxKW Use Motor Dataplate Info

1-22 MOTOR VOLTAGE 400 V

1-23 MOTOR FREQUENCY 50 HZ

1-24 MOTOR CURRENT xxx A Use Motor Dataplate Info

1-25 MOTOR NOM SPEED xxxx RPM Use Motor Dataplate Info

1-29 AUTO MOTOR ADAPT NO AMA ENABLE COMPLETE

1-90 MOTOR THERM PROTECTION ETR TRIP 1 THERMISTOR TRIP

1-93 THERMISTOR SOURCE NONE ANALOG INPUT 54

3-02 MIN REFERENCE 0.0 HZ 20.0 HZ

3-03 MAX REFERENCE 50.0 HZ

3-13 REFERENCE SITE HAND / AUTO REMOTE

3-15 REFERENCE 1 SOURCE ANALOG INPUT 53

3-41 RAMP UP TIME 45.0 SEC 15 SEC

3-42 RAMP DOWN TIME 90.0 SEC 20 SEC

PNU NAME FACTORY DEFAULT DCL DEFAULT

4-10 MOTOR SPEED DIRECTION BOTH DIRECTIONS CLOCKWISE

4-12 MOTOR SPEED LOW LIMIT 0.0 HZ 20.0 HZ

4-14 MOTOR SPEED HIGH LIMIT 50.0 HZ

4-16 TORQUE LIMIT MOTOR MODE 110 % 150 %

4-18 CURRENT LIMIT 110 % 150 %

4-19 MAX OUTPUT FREQUENCY 100 HZ

4-50 WARNING LOW CURRENT 0.0 A

4-51 WARNING HIGH CURRENT 99.0 A

4-52 WARNING LOW SPEED 0.0 RPM

4-53 WARNING HIGH SPEED 3000 RPM

5-01 TERMINAL 27 MODE INPUT

5-10 TERMINAL 18 DIGITAL INPUT START

5-11 TERMINAL 19 DIGITAL INPUT NO OPERATION

5-12 TERMINAL 27 DIGITAL INPUT COAST INVERSE

5-13 TERMINAL 29 DIGITAL INPUT JOG NO OPERATION



5-40 RELAY 1 FUNCTION ALARM RUNNING

5-41 RELAY 1 ON DELAY 0.01 SEC



5-42 RELAY 1 OFF DELAY 0.01 SEC

5-40 RELAY 2 FUNCTION RUNNING ALARM

5-41 RELAY 2 ON DELAY 0.01 SEC

5-42 RELAY 2 OFF DELAY 0.01 SEC

6-12 TERMINAL 53 MIN SCALING 4.00 mA

6-13 TERMINAL 53 MAX SCALING 20.00 mA

6.14 TERMINAL 53 LOW

REF/FEEDBACK VALUE

0.00 20.00

6.15 TERMINAL 53 HIGH

REF/FEEDBACK VALUE

50.00

6-20 TERMINAL 54 MIN SCALING 0.07 V

6-21 TERMINAL 54 MAX SCALING 10.0 V

6-50 TERMINAL 42 ANALOG OUT SPEED – 0 HIGH LIMIT SPEED 4-20mA

6.51 TERMINAL 42 MIN SCALING 0 % 40 %

6.52 TERMINAL 42 MAX SCALING 100 % 100 %

8.30 PROTOCOL FC MODBUS RTU

8.31 ADDRESS 1 2

8.32 BAUD RATE 19200 BAUD 9600 BAUD

8.33 PARITY/STOP BITS EVEN PARITY/1 STOP BIT NO PARITY/1 STOP

BIT



6.2.1 RWF 40.000A97 Default Burner Settings

SETTING FACTORY DEFAULT

DCL SETTING REMARKS

C111 9030 F000

0000

PRESSURE

TEMP

C112 0010 0000

C113 0110 0110

SCL 0.0 0.0

SCH 100.0 16.0

100

PRESSURE

TEMP

SCL2 0.0 0.0

SCH2 100.0 100.0

SPL 0.0 0.0

SPH 100 16.0

100.0

PRESSURE

TEMP

OFF1 0.0 0.0

OFF2 0.0 0.0

OFF3 0.0 0.0

DF1 1.0 1.0

DF3 1278 1278

OLLO -199.9 -199.9

OLH1 999.9 999.9

DTT 30 30

AL 0.0 0.0

HYST 1.0 1.0

PB.1 10.0 1.0

10.0

PRESSURE

TEMP

DT 80.0 25.0

RT 350 100.0

DB 1.0 1.0

TT 15.0 15.0

HYS.1 -5.0 -1.0

-5.0

PRESSURE

TEMP

HYS.2 3.0 0.5

3.0

PRESSURE

TEMP

HYS.3 5.0 1.0

5.0

PRESSURE

TEMP

Q 0.0 0.0

H 1.0 1.0

P 0.0 0.0

SP1 60.0 8.0

80.0

PRESSURE

TEMP

User definable



7 Commissioning

7.1 Basic settings

It is essential that heat output of the appliance is known in order that the correct fuel input can be

calculated and set. If there is any doubt at all with regard to the appliance rating, the manufacturer

should be consulted before the burner is fired. The calorific value of the fuel must be known and

measurement of the fuel input should be by meter wherever possible.

Do not leave the burner firing at a rate which is known to be or which may be excessive, this will

result in damage to the appliance.

The nett flue gas temperature should be taken throughout the process of setting combustion. The

figure will vary according to the construction of the appliance but will normally be in the range

of 180° to 250°C gross. – if in doubt what this figure should be, please consult the boiler/appliance

manufacturer.

Calculation of burner firing rate ( output ).

QfQn

kkW

[ ]

Qf = Burner Firing Rate ( Output ) kW

Qn = Boiler nominal thermal output ( kW )

k = Boiler Efficiency

Calculation of Gas Throughput at Nominal Boiler Output

VbQn

HU km h

*[ ]

3

Vb = Gas Throughput ( Fuel Input ) m3h.

Qn = Boiler nominal thermal output ( kW )

k = Boiler Efficiency

HU = Calorific Value of Fuel under Normal Conditions ( kWh/m3 )

Calculation of Gas Throughput for Boiler Firing Rate

VbQf

HUm h [ ]3

Vb = Gas Throughput ( Fuel Input ) m3h.

Qf = Burner Firing Rate ( Output ) kW

HU = Calorific Value of Fuel under Normal Conditions ( kWh/m3 )

Burner output ( kW ) =

Boiler output ( kW )

Boiler efficiency

The indicating scale on the air damper motor is calibrated so that zero represents the fully closed

position for the air damper. The indicated low fire and high fire positions will be the result of the



NOTE:

ON ANY BURNER, AN ALMOST INFINITE COMBINATION OF COMBUSTION

HEAD COMPONENTS AND SETTINGS MAY BE USED TO ACHIEVE OPTIMUM

EFFICIENCY AND A FLAME SHAPE TO SUIT A VERY WIDE RANGE OF HEAT-

RAISING APPLIANCES. THE MOST SUITABLE COMBINATION/SETTINGS

MUST BE DETERMINED DURING THE COMMISSIONING PROCEDURE.

adjustments described below, there are no pre-determined positions applicable to a particular

burner. The scale reading only represents the air damper opening and not the firing rate!

Adjustments to the burner combustion head (for example the position of the flame ring in the nose

cone) may be necessary during the `setting up` of a burner.

Details of the settings for a particular burner , firing a given make of boiler, cannot be given in a

manual of a realistic size, however, standard basic settings are given in section 3 of this manual.

The size and relative position of the flame ring to the cone will have an appreciable effect on the

volume and velocity of air passing over the flame ring and this must be taken into consideration

when setting the combustion efficiency, with adjustments made as necessary. Adjustment of the

flame plate in relation to the nose cone can be made by loosening the screws holding the nose cone

in place and moving the nose cone backwards or forwards. After adjustments have been made,

ensure that screws are retightened and sealed in place.

7.2 Start Gas Heat Input

The table below summarises the ignition gas rates for different burner configurations.

The start gas heat input must not exceed 120kW or the value given by the equation :

ts x Qs ≤ 100

where:



ts is the safety time in seconds (s):

Qs is the maximum start gas heat input expressed as a percentage of the main gas rate

This approximates to an ignition rate of less than one third of the maximum firing rate.

If the burner is fitted with a separate pilot, the start gas heat input of the ignition burner must not

exceed the value given by the equation:

ts x Qs ≤ 150

where:

ts is the safety time in seconds (s):

Qs is the maximum start gas heat input expressed as a percentage of the main gas rate

7.3 Pre-commissioning

Note: The following tests must be carried out before commissioning is started.

Check that the appliance has been filled to the correct level

Check that the appliance isolating valves are fully open.

Where fitted, check that the flue damper is locked in the open position.

Check that the flue-draught stabiliser moves freely

Check that the gas supply is guaranteed and is at the correct pressure.

Check that the gas meter is the correct size.

Ensure that a manual gas isolation valve is positioned as close as possible to the burner and

that all gas pipe work is adequately supported.

Check that the external electrical connections are in accordance with the appliance

manufacturers wiring instructions.

Make certain that both fuel supplies and electrical supplies have been isolated.

Ensure that all gas, oil and electrical connections are tight as connections may come loose

during transportation.

Check the electrode gap to be 3mm at the narrowest point of the ignition electrode (twin)

and the tip of gas ignition electrode is 3mm away from the gas nozzle outlet.

Set the firing rate control switch to `low fire` to ensure that the burner will remain at low

fire after light-up.

Hot water boilers - check operation of the control and limit thermostats and that the boiler

has been filled with water.

Steam boilers - confirm the operation of the boiler feed pump and switch, and check that

the water level controls are working.

After the initial firing of the boiler, do not leave the unit operating in an unmanned boiler

house unless the boiler on/off control has been operated and set at a suitable figure and the

flame failure system on the burner has been checked.



7.4 Commissioning – High Low and Pneumatic Modulation burners - Firing on Gas

7.4.1 Dry run

Note: Gas leak checks must be carried out using a suitable non-corrosive leak detection fluid.

Check for gas leaks on meters, governors and all mains gas supply pipe work.

Ensure all pipework leading up to the burner main gas valve has been purged according to

IGE/UP/1 Soundness testing and Purging of Industrial & Commercial Gas Installations

Ensure that the burner manual isolation valve is closed.

Check that all isolation valves in the main gas supply pipe work are open.

Remove or loosen the gas inlet pressure test point on the inlet side of the gas valve and open

the burner isolation valve until all air has been purged between the isolation valve and the

burner gas valve.

When this has been done, close the isolation valve.

Note: For the following tests a digital manometer will be required.

7.4.2 Check for leaks through the automatic gas valve.

Connect the manometer to the gas inlet test point on the automatic gas valve, open the manual gas

isolation valve for two seconds and then close it again.

The pressure shown on the manometer should remain constant.

7.4.3 Check rotation of burner fan motor

Switch on mains electrical supply. Momentarily 'blip' the burner fan connector and check rotation

of fan against direction of rotation sticker fixed to the rear of the burner. If motor rotates in the

wrong direction, changeover two of the incoming 3 phase supply. Repeat test to ensure rotation is

now correct.

7.4.4 Check for correct control sequence.

Open manual gas isolation valve for two seconds and then close it again, sealing the gas

between the automatic gas valve and the isolation valve.

Check that all time switches, room thermostats etc are in the òn` position and that the boiler

thermostat is set to the required temperature.

Switch on the mains electrical supply.

Select 'Gas' on the control system

The control box will commence the starting sequence which, depending on the control box,

will average:-

Prepurge time 30 seconds

Pre-ignition time 3 seconds

Pilot proving time 3 seconds

When the pilot proving time is reached, the automatic gas valve is energised and will

release the gas trapped between the valve and the closed isolation valve.

The burner will then stop because the pressure acting upon the gas pressure proving switch

will be reduced due to the isolation valve being closed.

Switch off the electrical supply on completion of this test.



7.4.5 Firing the burner

Ensure that the heat demand will allow an extended run, otherwise the burner may not

continue to fire throughout the time required for throughput measurement or commissioning

procedure.

Unscrew or loosen the outlet gas pressure test point on the gas valve and connect a

manometer.

Open the manual gas isolation valve.

Switch on the mains electrical supply and, if the control box is locked out (indicated by the

reset button being illuminated) press the lockout reset button. For electrical modulation

systems, please consult relevant manual.

Provided all control devices, thermostats etc are in the òn` position the burner control box

will start the operating sequence. For information relating to sequence of operation please

refer to section 5.

If the control sequence fails to start, check for correct setting of the gas pressure proving

switch.

The amount of gas flowing through the valve can be adjusted by using the ‘ ’ and

‘ ’ and is proportional to the amount of combustion air set by the air damper

motor. Cam setting for the air damper have been described in section 4.1.

‘ ’ is used to set the Low Fire rate and ‘ ’ is used to adjust the high fire

rate. A combination of the two settings will define an operating line between high fire and

low fire and the valve will maintain the air/gas ratio across this range. Full information on

the gas multiblock may be found in section 4.

Adjustment of ‘ ’ will have an effect on the setting of ‘ ’ and vice-

versa. It may take 3 or 4 fine adjustments at both high fire and low fire to ensure good

combustion at both ends.

ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS.

7.4.6 Combustion values and results

All combustion readings must be taken with an approved and correctly calibrated test kit.

The following combustion values should be reached:-

Low Fire

CO content 0 - 20 ppm

CO2 content 9 - 11 %

O2 content 5.4 - 2%

High Fire


CO2 content 10 - 11%

O2 content 3.6 - 2%

In all cases the CO figure should not exceed 100mg/m3 maximum.

The nett flue gas exit temperatures should be taken throughout the process of setting the

combustion.

The figures will vary according to the type of appliance but for shell and sectional boilers will be in

the range of 180 - 250C gross.

Always keep the exhaust flue gas temperatures within the manufacturers recommended

range and ensure that the appliance is not over or under fired. Warm up the boiler, or raise

steam in accordance with appliance manufacturer’s instructions.



7.4.7 Adjustment of Gas Proving Pressure Switch

Loosen the screw in the gas inlet measuring point, connect a manometer and remove the clear

plastic cover from the gas pressure detector.

Switch on the burner and allow to fire.

Close the burner manual gas isolation valve slowly until the gas pressure is reduced to 50%.

Adjust the numbered black plastic ring on the gas pressure detector until the burner switches off.

Switch off the mains electrical supply to the burner, remove the manometer and seal the test point

screw.

Open the manual gas isolation valve and switch on the burner.

7.5 Oil Firing

All burners using oil as a fuel are fired before despatch as part of the standard test programme. This

does not mean that the pump pressure or any other adjustment applying to the oil system is

necessarily correct for the application.

Commissioning of the burner must include confirming that the nozzle size and characteristics are

suitable, calculating the fuel pressure required to give boiler M.C.R. and ensuring that, subject to

the requirements given below, the firing rate is correctly set.

The following text in included on the basis that the burner has been commissioned on gas and that

the boiler or appliance controls have been set.

The change - over of fuels is made by operation of the selector switch on the burner control cabinet.

This selector switch controls two contactors which electrically isolate one fuel from the other. On

electronic modulating burners, fuel selection can be made via the keypad.

For change-over to either fuel the switch selection is made through the 'off' position which causes

the burner control box to extinguish the flame before recycling.

The starting cycle will not immediately commence because it will be necessary for the burner

motor to slow down, reducing the air flow to a level which allows the air pressure switch to return

to the 'no' air position.

Note: Even on oil firing the leak detection cycle will be activated.

Before changing to oil firing, ensure that the oil pump has been properly vented and flooded.

No mechanical changes or re-adjustment of components are required for the burner to be changed

from one fuel to another.

Before the first firing on oil, it is always advisable for the availability of fuel, fire valves open etc,

to be confirmed.

Check that the burner will remain at low fire.

7.5.1 Setting the Firing Rate, High / Low Oil Burners

Step 1

Set the Low Fire air damper motor setting to between 1 and 2 on the scale and the high fire

air damper setting to between 5 and 6 on the scale. Set O2 to approx 3 on the scale.

Ensure that the High / Low switch is in the low fire position and switch on the burner.

Momentarily 'blip' the oil pump contactor to check for correct rotation of pump - ensure it

rotates according to rotation sticker fixed to rear of the motor. If rotation is incorrect, swap



over two pluses on the pump motor. Do not swap the mains electrical feed as this will also

reverse the burner fan motor rotation.

Start the burner and allow to go through pre-purge cycle. When the burner reaches its

ignition position, the ignition transformer is switched on, followed by the fuel pump motor,

and then the two solenoid valves, which should result in the burner lighting.

Set the pump pressure to approx 25 bar.

Adjust the low fire air position to give the following figures:

Carbon Dioxide: 11 - 14%

Smoke Number: 0 - 1 (

Excess Oxygen: 3 - 6%

Nett Flue Gas Temperature: 180 - 220ºc

Step 2

Allow burner to move to High Fire position. On its way to High Fire, the V2 Oil Valve will

energise, thus passing oil into the second nozzle.

Once at High Fire, adjust air damper to give combustion figures similar to above.

Switch between Low and high Fire, checking the firing rate and combustion, ensuring that

consistent figures and smooth, reliable light-up are being obtained.

Listen for signs of flame instability.

With the burner firing, remove and cover the photocell, ensuring that the burner goes

immediately to lockout.

Warm up the boiler or raise steam slowly, and in accordance with the manufacturer's

instructions.

After running for a reasonable amount of time, remove the combustion head and check for

any oil impingement, oil leaks, or fouling at the flame plate.

If necessary, make adjustments to the combustion head to cure this.

Check the flame ring for indications of overheating or impingement by the oil spray.

The basic, relative positions of the combustion head components are given in section 3 of this

manual, but the principles to be followed are that:-

1. The ignition electrodes must be positioned so that the spark, which `strikes` at the narrowest

point is blown forward by the combustion airflow on to the widest point of the `horns`. This

will ensure that the arcing takes place within the cone of atomised fuel, with a consequent

immediate ignition of the fuel.

Note that if the electrodes are set too far forward, they will be subjected to continuous

impingement by un-burnt fuel, some of which will carbonise, quickly reducing the intensity

of the spark and leading to poor ignition.

2. The relative position of the flame ring must give a flame which is ànchored` on to the front

face of the ring. The slotted vanes must be opened enough to allow the passage of an

adequate amount of air, which because of the swirl effect imparted, will be a major

stabilising factor. If the vane gap is irregular, the flame shape will be affected and soot will

build up at the points which restrict the air flow.

If the nozzle is too near to the flame ring, the flame will tend to `lift off`, giving very

unreliable ignition and a degree of instability which will make reliable operation, especially

when modulating from high to low fire.

3. The combustion head as an assembly, must be central in the draught tube, otherwise the air

velocity round the outside of the flame ring ( and therefore of the flame ) will vary in



relation to the gap through which the air is passing, causing poor flame shape and

impingement on the furnace structure.

4. Where divergent ( expanded ) nose cones are used, the cone itself should be positioned

relative to the flame ring and allow an adequate volume of air for combustion, but at the

same time, give a velocity which is high enough to assist in shaping the flame to give

optimum combustion.

While the design of the combustion head is the major factor in obtaining maximum

combustion efficiency, careful setting of the various component parts is also important.

When a burner has been in service for a period long enough for its performance to be

confirmed and before the settings have been disturbed, the relative dimensions of the

combustion head components should be recorded, so that after dismantling for maintenance,

correct reassembly can be assured.

Set the high/low thermostat or pressure switch to a lower figure than the on/off control. The

difference should take account of demand, bringing the burner back to low fire early enough

to slow down any boiler pressure or temperature rise if the heat demand is less than the

boiler M.C.R. and reduce the on/off cycling of the burner. Equally the burner must revert to

its high fire rate in time to maintain the pressure or temperature above a figure which is

determined by site conditions.



7.6 Electronic Modulating Burners

7.6.1 Gas Butterfly Valve

Control of the gas supply to the burner is performed using a butterfly valve.

material specification of blade and spindle can be altered depending on gas

type, E.G. Stainless Steel can be specified for Bio-gas.

Check the butterfly valve has been correctly set to zero - Please consult

manual for details. More details on the butterfly valve can be found in the

component section.

7.6.2 Oil Metering Valve

The oil metering valve is used to control the amount of oil returning from the

spill back oil nozzle line. On spill back systems, the witness mark on the

inner spool piece must be set to 'B'.

Set the pointer to zero - Please consult manual for details. With the pointer set to zero, this

represents maximum flow through the metering valve. As the valve modulates up to 90º, the valve

closes off, also closing off the return spill line from the oil nozzle line and

therefore increasing the firing rate. More details on the oil metering valve can be

found in the component section.

7.6.3 Adjustment of air pressure proving switch

Check the air pressure proving switch and, if necessary, set to 50% of

differential pressure.

Example of adjustment:-

Negative pressure ( – ) measured 4 mbar

Positive pressure ( + ) measured 5 mbar

Differential pressure is - 9 mbar

Switch off point of pressure switch is 4.5mbar

From this point all commissioning procedures are dictated by the Ratiotronic 6000 manual.

ALWAYS CHECK THE COMBUSTION READINGS AFTER MAKING ADJUSTMENTS

IMPORTANT!

When commissioning burners fitted with Electronic Modulating Control Systems, the

respective operating manuals must be followed. Only competent and trained personnel are

permitted to commission burners fitted with these controls.



7.6.4 Ratiotronic programming

The Ratiotronic 6000 burner control system is generally pre-programmed in the factory prior to

despatch. However it is important that the parameters are checked against the lists supplied with the

test data supplied with the burner.

The combustion engineer must be competent with such a controller and be fully trained in burner

commissioning before proceeding any further.

This manual must be used in conjunction with the Ratiotronic 6000 manual at all times.

7.6.5 Setting the servo motors

Please refer to section 5 of the Ratiotronic manual.

In general the drive servo motors are allocated as follows:

Drive 1: Gas Butterfly valve

Drive 2: Oil Metering Valve

Drive 3: Air damper servo motor

Drive 4: Inverter

7.6.6 Burner Commissioning

All burners using oil as a fuel are fired before despatch as part of the standard test programme. This

does not mean that the pump pressure or any other adjustment applying to the oil system is

necessarily correct for the application.

Please now refer to ‘Section 6.6 Commission Ratio Mode’ of the Ratiotronic 6000 manual for

details on how to commission the burner.

7.6.7 Combustion values and results

All combustion readings must be taken with an approved and correctly calibrated test kit.

The following combustion values should be reached:-

Low Fire


CO2 content 9 - 11 %

O2 content 5 - 2%

High Fire


CO2 content 10 - 11%

O2 content 3.6 - 2%

In all cases the CO figure should not exceed 100mg/m3 maximum.

The nett flue gas exit temperatures should be taken throughout the process of setting the

combustion.

The figures will vary according to the type of appliance but for shell and sectional boilers will be in

the range of 180 - 250C gross.

Always keep the exhaust flue gas temperatures within the manufacturers recommended

range and ensure that the appliance is not over or under fired. Warm up the boiler, or raise

steam in accordance with appliance manufacturer’s instructions.



8 Burner Maintenance Schedule

The following schedules are only to be taken as a guide to those persons responsible for day to day

maintenance of the burners. Details of a service agreement covering the major items of routine

servicing are available on request.

An annual check by factory trained technicians is strongly advised.

All control circuit components, fire valves and other safety devices should have a functional check

at not greater than annual intervals.

Maintenance and inspection of boilers or other appliances must meet the requirements of the

manufacturers' schedules and of the insurers. It is usually more convenient to carry out burner

maintenance after the completion of the boiler inspection or cleaning, so that the burner can be fired

and the combustion reset to optimum figures.

The measurements given in the various combustion head drawings in this manual are to be regarded

as datum figures only. During commissioning, alterations may be made to the relative positions, or

to the components themselves, to suit the particular application.

Therefore, before dismantling the combustion head, take note of the measurements concerned and

record them on the manual's drawings. It is important that where possible components of the same

type and size are fitted as replacements.

The commissioning certificate for the burner should be available, to be used as a reference for the

fuel input and combustion figures which will give boiler MCR and the highest efficiency level.

8.1 Opening the Burner

To open the burner, the two nuts securing the hinge section to the fan section must be removed. The

burner will swing open on its hinge offering full access to all combustion head components.

When necessary checks/repairs have been carried out, close up in reverse order ensuring that the

locking nuts are fully tightened.

REMEMBER!

ELECTRICAL AND FUEL SUPPLIES MUST BE ISOLATED BEFORE ANY

MAINTENANCE WORK IS CARRIED OUT ON THE BURNER.



8.2 Minor Maintenance

(a) Check the operation of the flame failure system daily by deliberately locking out the burner.

This can be achieved by either removing the UV cell, or on burners fitted with ionisation

probes isolating the gas supply to the burner.

(b) Where fitted, check and regularly clean the UV cell window with a soft cloth.

(c) Inspect the burner control cabinet to ensure that all indicator lamps are serviceable.

(d) Make a general check for cleanliness and security.

(e) As convenient, make an inspection of the combustion head components for cleanliness,

security and serviceability.

(f) Check the main gas valves for external hydraulic fluid leaks.

(g) Confirm the security of all linkages, locking nuts and any component parts fitted to the

burner

(h) Where a micro-ammeter is fitted make regular checks to confirm that the UV cell output

does not significantly deteriorate.

8.3 Major Maintenance

Take adequate safety precautions against the small amount of gas which escapes when gas train

components are removed.

Carry out all of the maintenance tasks listed above, plus the following:

(a) Remove the upstream pilot valve and determine the amount of dust etc. which is present. If

a substantial quantity is found, remove the upstream main gas valves from the burner and

clean the seats (Unibloc only, see 'Unibloc' section of this manual for actuator removal).

The Siemens valve is a sealed unit – any unauthorised opening will invalidate warranty.

(b) Check and clean any gas filters in the site pipework if significant quantities of dust or scale

are found. Make a request to the gas region for similar work on the service filter which

protects the meter

(c) Confirm correct operation of electrical components, e.g. control boxes, motor starters etc

and check tighten all electrical terminals.

(d) The nominal life of a U/V cell is 10,000 hours, subject to regular checks of the cell output

as registered on the micro-ammeter (which might indicate an earlier deterioration) the cell

should be changed every third year.

(e) Disconnect the air shutter linkage at the shutter spigot. Move the shutter by hand to confirm

freedom of movement. Clean as necessary (the PTFE bearing surfaces need no lubrication

but will require replacement when worn)

(f) Inspect the refractory of the burner mounting plate. Make good any defects in refractory or

sealing

(g) Ensure that boiler furnace sight glasses are clean and that their sealing is flue gas-tight.

(h) When the inspection and any rectification work has been completed on the burner/boiler,

bring the unit up to working temperature (slowly).

(i) With the boiler on line, confirm that the fuel throughput and combustion efficiency are

equal to the 'commissioned' figures.



8.4 Dismantling and Re-assembly of Burners

Combustion Head Removal

The combustion head can be removed, as a unit, for maintenance purposes. Before commencing

refer to the combustion head drawings in the exploded diagram section at rear of this manual for

relevant positions of the various components.

(a) Open the burner, as described in the burner maintenance schedule.

(b) Disconnect the probe/HT lead and, where a UV cell is fitted, remove this from its retaining

clip and move to a safe place.

(c) Loosen the jacking screw in the mounting hinge section opposite the gas entry, as shown in

the illustration below.

(d) Pull the nozzle line spigot out of the gas entry.

(e) Withdraw the nozzle line complete, out of the blast tube.



(f) Re-assemble in reverse order, ensuring that a new gas head seal is fitted.

(g) Check the combustion head is correctly aligned in the blast tube and that the seal is gas

tight.

(h) Close and lock-up the burner

Burner Motor Replacement

(a) Disconnect the probe and ignition leads from the combustion head and withdraw them and,

where necessary the UV cell from the mounting casting.

(b) Disconnect air pressure switch and hinge switch cables. Ensuring that all cables are properly

marked for ease of re-connection.

(c) Ensure that the burner door locking nuts are fully tightened.

(d) Disconnect all mains power connections and other electrical wiring between the burner

panel and the boiler or other electrical panels again ensuring cables are marked.

(e) Disconnect the motor wiring at the panel end (ensure that all cables are identified and that

the wiring connections on the replacement motor are the same as on the original).

(f) Remove the air damper drive linkage.

(g) On the TD3, TD4 and TD5 burners it will be necessary to electrically disconnect the air

damper modulation motor.

(h) Take out the four fixing bolts and remove the modulation motor mounting bracket .

(i) Using suitable lifting gear take the weight of the burner by its lifting eye.

(j) Remove the ring of screws which secure the two halves of the fan case.

(k) Remove the rear half of the burner (half fan case, motor, fan, panel) and place on a bench or

clean floor area.

(l) Remove the fan retaining bolt from the end of the motor shaft and carefully remove the fan

taking care not to misplace the drive key.

(m) Remove the motor by releasing the four retaining bolts at the rear of the main air shutter

casting.

(n) Re-assemble in reverse order, ensuring that the motor shaft is properly greased before the

fan is fitted.

Gas Valve Actuator -Removal/Replacement

Removal of gas valve actuators must only be carried out by suitably qualified personnel. Full

details of removal/replacement procedures for all standard actuators fitted by Dunphy Combustion

are given in the 'Unibloc' section of this manual.

NOTE: THE FAN AND BOSS MUST BE

REMOVED COMPLETE AS A SINGLE UNIT UND ER NO CIRCUMSTANCES MUST THE



9 Faults and fault finding

9.1 Ratiotronic 6000/6006

Faults relating to electronic modulation burners must refer to the Ratiotronic 6000 controller

manual – Section 9.



10 Useful Information

Common Conversion Tables

To Convert Into Multiply by

Bars

kg/m2

1.020 x 104

Bars

p.s.i.

14.5

Bars

kg/cm2

1.01972

Btu

J

1054.8

Btu

kg.cal

0.2520

Btu/hr

kW

2.928 x 104

Btu/lb MJ/Kg 2.326 x 10-3

ºC.

ºf.

(Cº x 9/5) + 32

cm.Hg.

ft. of H20

0.4451

cm.Hg.

p.s.i.

0.1928

ft.

metres

0.3048

gallons (US)

litres

3.785

gallons (Imperial)

litres

4.546

gallons (US)

gallons (Imperial)

0.83267

Hp

kW

0.7457

hp (boiler)

kW

9.803

Inches

cm.

2.54

Inches of H2O

mb.

2.54

J

Btu

9.48 x 10-4

kg.Cal.

Btu

3.968

kg/cm²

p.s.i.

14.2233

kW

Btu/hr.

3412

kW

kg.cal/min.

14.34

Litres

gallons (Imperial)

0.21997

Litres/minute

gallons(Imp.)/second

3.669 x 10-3

Metres

ft.

3.281

p.s.i.

bars

6.895 x 10-2

p.s.i.

mbars

69



RECORD OF COMMISSIONING VALUES

SITE:

ADDRESS:

BURNER TYPE:

SERIAL NUMBER:

BOILER TYPE:

SERIAL NUMBER:

BOILER OUTPUT:

OPERATING TEMP/PRESS:

DATE OF COMMISSIONING:

ENGINEERS NAME:

FUEL:

PUMPED RING MAIN/GRAVITY SUPPLY?

NOZZLE TYPE & SIZE

OIL PUMP

WIRING DIAGRAM NO

Firing Rate Position

Low Fire

1

2

3

4

5

6

7

8

9

High Fire

10

Burner Output

CO2

CO

O2

NOX

Nett Flue Gas Temperature ºC

Smoke Number

Ambient Temperature

Efficiency

Electronic

Channel 1 - Fuel

Modulation

Channel 2 - Air

Furnace Pressure

Fan Pressure

Pump Outlet Pressure bar

Oil Return Pressure ( Spill ) bar

Boiler Temperature ºC

Boiler Pressure





11 Exploded Diagram & Spare Parts List 11.1 Modulating Oil Modulating Gas Setup





ITEM QTY. DESCRIPTION DWG/PART No.

1 1

TD410 LOW NOx COMBUSTION HEAD ASSEMBLY

TD415-420 LOW NOx COMBUSTION HEAD ASSEMBLY

TD410 COMBUSTION HEAD ASSEMBLY

TD415-420 COMBUSTION HEAD ASSEMBLY

GA23554

GA23555

GA23556

GA23558

2 1 T4 VANE CASTING GA08715

3 1

T410 FAN IMPELLOR (WHITE)

T415 FAN IMPELLOR (BLUE)

T420 FAN IMPELLOR (BLACK

GA8765

GA8764

GA8763

4 1 T4 BODY (FAN HALF) GA08716

5 1 EYEBOLT T4 16MM 58mm O/D x32mm I/D EYEBLT00100

7 1

TD410 7.5KW FAN MOTOR

TD415 11KW FAN MOTOR


MOTORF01210

MOTORF01235

MOTORF01250

8 1 ANODISE OUTER SHUTTER TD410, TD415

ANODISE OUTTER SHUTTER TD420

GA15127

GA17290

9 1 ANODISE INNER SHUTTER TD410, TD415

ANODISE INNER SHUTTER TD420

GA15125

GA17210

10A 1 SILENCER FOR TD410, TD415

SILENCER FOR TD420

GA08891

GA08893

10B 1 T410/415 SNORKEL SILENCER WITH CHAMFERED CORNERS

T420 SNORKEL SILENCER WITH CHAMFERED CORNERS

GA21875

GA21504

10C 1 SNORKEL SILENCER MESH GA16838

11 1 SPACER FOR MOD PLATE GA07961

12 2 ROD END BEARING BEAROS00250

13 1 SERVO MOTOR LINKARM GA18765

14 1 MOD PLATE GA17188

15 1 ETC6027 CANBUS SERVO MOTOR 12Nm ETCRAT00745

16 1 T4 CONTROL PANEL MOUNTING BRACKET GA9093

17 1

542 ELECTRICAL ENCLOSURE



GA10724

GA10720

GA12409

18 1

DOOR FOR 542 ELECTRICAL ENCLOSURE



GA10726

GA10722

GA10723

19 1 SIDE ENTRY GASKET GA08990

20 1 GAS TRAIN FLANGE 80 GA07099

21 1 BUTTERFLY VALVE 80mm GA17187

22A 1

T4 UNIBLOC SIDE ENTRY ASSEMBLY DN65



GA23518A

GA23518B

GA23518C

22B 1

T4 VGD40 SIDE ENTRY ASSEMBLY DN65



GA23529A

GA23529B

GA23529C

23 1 MALE STUD COUPLING 10MM x 3/8" BSP COMPAD00490

24 1 10mm BUNDI TUBE BUNDIT00145

25 1 PRESSURE SWITCH PRESWI00246

26 1 INNER NYLON ROLLER GA5761A

27 1 OUTER NYLON ROLLER GA5761B

28 1 Z TYPE MOUNTING GASKET

Y TYPE MOUNTING GASKET

GA11741

GA11742

29 1 QRA2 UV CELL WITH BRACKET 12041



30 1 JACKING SCREW FASHEX00150

31 2 OIL ELECTRODE IGELEC00110

32 1 OIL TUBE SUPPORT SPIDER GA12370

33 4 SPLIT ELECTRODE BUSH GA8264

34 1 ART1400 BURNER GUN GA21876

35 2 POSITIONAL ELBOW 10-4L 10mm COMPAD00550

36 12 1/4"BSP DOWTY 'BONDED' SEAL SEADOW00105

37 4 1/4" BSP YORKSHIRE FTG. BRASS PLUG YORFIT00510

38 2 SWIVEL ELBOW 10mm MSE 10-4 L COMPAD00505

39 1 TWIN PORT SANDWICH BLOCK (INSIDE) GA9178A

40 2 SANDWICH BLOCK INNER O-RING ORINGS00180

41 1 SANDWICH BLOCK OUTER O-RING 0RINGS01025

42 1 TWIN PORT SANDWICH BLOCK (OUTSIDE) GA9178B

43 1 MALE STUD COUPLING 10mm MMC 10-4 L COMPAD00485

44 5 STANDPIPE ADAPTOR 10mm MSA 10-4 L COMPAD00535

45 3 EQUAL TEES 10mm 10 L COMPAD00520

46 4 MOTOR HANGER PLATE SPACER GA7961

47 1 VARIOTRONIC OIL METERING VALVE ASSEMBLY GA16090

48 2 1/4" MINI BALL VALVE VALOIL00110

49 2 M5 COPPER WASHER COPWAS00025

50 2 0 - 600 PSI PRESSURE GUAGE PRESGA00100

51 3 MALE STUD COUPLING 10mm X 3/8" MMC 10-6 L COMPAD00490


53 2 PRESSURE SWITCH ADAPTOR BANMAN00170

54 2 1/4" COPPER WASHER COPWAS00075

55 1 SAUTER HIGH OIL PRESSURE SWITCH

BAILEY HIGH OIL PRESSURE SWITCH

PRESWI00570

PRESWI00700

56 1 BRIDGE HANDLE CONTOL02285

57 2 STANDPIPE ADAPTORS 10mm MSA 10-8 L COMAD00545


59 1 1/2" LUCIFER OIL SOLENOID VALVE SOLOIL00360

60 3 MALE STUD COUPLING 10mm x 1/2" MMC 10-8 L COMPAD00495

61 1 3/8" BSP BANJO BOLT #7 x 70 GA10382


63 1 MANIFOLD No. 4 WITH VALVE CLUSTER GA16780

64 1 COPPER WASHER 3/8" COPWAS00100


66 1 1"BSP 'HEAVYWEIGHT' BARREL NIPPLE PIPNIP01340

67 1

DH1-1-CLOCKWISE ROTATION


DH1-1-ANTI-CLOCKWISE ROTATION

DH1-1-ANTI-CLOCKWISE

PUMDUN01012

PUMDUN01010

PUMDUN01025

PUMDUN01020

68 1 POSITIONAL ELBOW 3/4" x 1/2" CONELB00125

69 2 OIL SOL VALVE LUCIFER 1/2" N/C SOLOIL00240

70 1 OIL MANIFOLD No. 1 GA16777


72 1 MOUNTING BRACKET FOR VALVE CLUSTER FITTET TO DH-1 GA10190

73 1 D.90 MOTOR BELL HOUSING GA05900

74 1 PUMP COUPLING ASSEMBLY PUMZCP00665



75 1 1.1kW 2 POLE PUMP MOTOR MOTPUM00120

76 1 MOTOR HANGER BRACKET GA10450

77 1 BERGER LAHR SERVO MOTOR SERVBLO00100

78 1 VARIOTRONIC OIL VALVE MOUNTING BRACKET GA16089

79 1 10mm DIAMETER BUNDI TUBE GA23514A

80 1 10mm DIAMETER BUNDI TUBE GA23514B

81 1 10mm DIAMETER BUNDI TUBE GA23514C

82 1 10mm DIAMETER BUNDI TUBE GA23514D

83 - 10mm DIAMETER BUNDI TUBE BUNDIT00115

84 1 SAUTER LOW OIL PRESSURE SWITCH

BAILEY LOW OIL PRESSURE SWITCH

PRESWI00400

PRESWI00705



11.2 Modulating Oil Modulating Gas with DH2 Pump (TD420 Only)






1 1 TD415-420 LOW NOx COMBUSTION HEAD ASSEMBLY


GA23555

GA23558


3 1




GA8765

GA8764

GA8763



7 1 TD420 15KW FAN MOTOR MOTORF01250

8 1 ANODISE OUTER SHUTTER TD420 GA17290

9 1 ANODISE INNER SHUTTER TD420 GA17210

10A 1 SILENCER FOR TD420 GA08893

10B 1 T420 SNORKEL SILENCER WITH CHAMFERED CORNERS GA21504







17 1




GA10724

GA10720

GA12409

18 1




GA10726

GA10722

GA10723




22A 1




GA23518A

GA23518B

GA23518C

22B 1




GA23529A

GA23529B

GA23529C






28 1 Y TYPE MOUNTING GASKET GA11742

29 1 QRA2 UV CELL WITH BRACKET 12041

30 1 JACKING SCREW FASHEX00150



33 1 FLAME PLATE GA10613

34 2 IGNITION ELECTRODE IGELEC00110


36 1 SHELL HEAD FOR OIL BURNERS GA8233A

37 1 ART1400 OIL BURNER GUN GA21876

38 2 POSITIONAL ELBOW 10-4L COMPAD00550




40 4 1/4" BSP YORKSHIRE BRASS PLUG YORFIT00510





45 1 VARIOTRONIC OIL METERING VALVE ASSEMBLY & PARTS

LIST GA16090

46 1 VARIOTRONIC OIL VALVE MOUNTING BRACKET GA16089

47 1 BERGER LAHR SERVO MOTOR 30039

48 3 EQUAL TEES 12mm 12 L COMPAD00455

49 2 1/4" MINI BALL VALVE MBV 14S VALOIL00110

50 2 M5 FLAT COPPER WASHER COPWAS00025


52 2 STANDPIPE ADAPTORS 12mm MSA 12-8 L COMAD00480


54 2 OIL SOL VALVE LUCIFER 1/2" N/C SOLOIL00240

55 1 OIL MANIFOLD No. 1 GA16777



58 1 SAUTER LOW OIL PRESSURE SWITCH

BAILEY LOW OIL PRESSURE SWITCH

PRESWI00400

PRESWI00705

59 1 OIL SOL VALVE LUCIFER 1/2" N/C 230V SOLOIL00360



62 1 MANIFOLD No. 6U WITH DH-2 VALVE CLUSTER GA16771

63 1 REDUCING NIPPLE, 1"-3/4" PIPNIP01450



66 1 DH2 PUMP SERIES

PUMDUN02013

PUMDUN02014

PUMDUN02015

PUMDUN02016

67 3 3/4" BSP DOWTY SEAL SEADOW00120

68 1 POSITIONAL ELBOW 1" x 3/4" CONELB00125

69 1 MOUNTING FLANGE DH2 FUEL UNIT GA7928

70 1 MOUNTING BRACKET FOR VALVE CLUSTER FITTET TO DH-2 GA10228


72 1 PUMP COUPLING PUMZCP00665

73 1 3kW 2 POLE PUMP MOTOR MOTPUM00310


75 2 PRESSURE SWITCH ADAPTOR BANMAN00170

76 2 1/4" COPPER WASHER COPWAS00075

77 1 SAUTER HIGH OIL PRESSURE SWITCH

BAILEY HIGH OIL PRESSURE SWITCH

PRESWI00570

PRESWI00700

78 1 10mm BUNDI TUBE GA23870A

79 1 10mm BUNDI TUBE GA23870B

80 1 10mm BUNDI TUBE GA23870C



11.3 High Low Oil High Low Gas Setup (TD410 Only)






1 1 TD410 LOW NOx COMBUSTION HEAD ASSEMBLY


GA23554

GA23556


3 1




GA8765

GA8764

GA8763



7 1 TD410 7.5KW FAN MOTOR MOTORF01210

8 1 ANODISE OUTER SHUTTER TD410, TD415 GA15127

9 1 ANODISE INNER SHUTTER TD410, TD415 GA15125

10A 1 SILENCER FOR TD410, TD415 GA08891

GA08893

10B 1 T410/415 SNORKEL SILENCER WITH CHAMFERED CORNERS GA21875







16 1 T6 CONTROL PANEL MOUNTING BRACKET GA9093

17 1




GA10724

GA10720

GA12409

18 1




GA10726

GA10722

GA10723



21 - - -

22 1




GA23524A

GA23524B

GA23524C








28 1 MOUNTING GASKET GA11741




32 2 HIGH LOW OIL NOZZLE SEE PROD. SHEET

33 2 TWIN NOZZLE BLOCK GA5406










43 1 1/4" BSP OIL MANIFOLD BLOCK 4 PORT GA13237










53 1





PUMDUN01012

PUMDUN01010

PUMDUN01025

PUMDUN01020





58 1 1/2" BSP YORKSHIRE FITTING YORFIT00530







72 1 PUMP COUPLING INSERT PUMZCP00665



75 4 MOTOR HANGER BRACKET SPACER GA7961





80 1 10mm BUNDI TUBE GA23517D




11.3 Modulating Gas High Low Oil Setup (TD410 Only)






1 1

TD410 LOW NOx COMBUSTION HEAD ASSEMBLY

TD415-420 LOW NOx COMBUSTION HEAD ASSEMBLY



GA23554

GA23555

GA23556

GA23558


3 1 T410 FAN IMPELLOR (WHITE) GA8765



7 1

TD410 7.5KW FAN MOTOR



MOTORF01210

MOTORF01235

MOTORF01250

8 1 ANODISE OUTER SHUTTER TD410, TD415 GA15127

9 1 ANODISE INNER SHUTTER TD410, TD415 GA15125

10A 1 SILENCER FOR TD410, TD415 GA08891

10B 1 T410/415 SNORKEL SILENCER WITH CHAMFERED CORNERS GA21875







16 1 T4 CONTROL PANEL MOUNTING PLATE GA9093

17 1




GA10724

GA10720

GA12409

18 1




GA10726

GA10722

GA10723




22 1




GA23524A

GA23524B

GA23524C






28 1 MOUNTING GASKET GA11741






32 2 HIGH LOW OIL NOZZLE SEE PROD. SHEET

33 2 TWIN NOZZLE BLOCK GA5406










43 1 1/4" BSP OIL MANIFOLD BLOCK 4 PORT GA13237










53 1





PUMDUN01012

PUMDUN01010

PUMDUN01025

PUMDUN01020





58 1 1/2" BSP YORKSHIRE FITTING YORFIT00530





72 1 PUMP COUPLING INSERT PUMZCP00665





75 4 MOTOR HANGER BRACKET SPACER GA7961





80 1 10mm BUNDI TUBE GA23517D




11.4 Multi-Oil Multi-Gas Exploded Diagram





ITEM QTY. DESCRIPTION TD410 TD415 TD420

PART No. PART No. PART No.

1 1 T4 HINGE CASTING GA8714 GA8714 GA8714

2 1 T4 VANE CASTING GA8715 GA8715 GA8715

3 1 T4 IMPELLOR GA8765 GA8764 GA8763

4 1 T4 FAN MOTOR MOTORF01210 MOTORF01230 MOTORF01250

5 1 T4 PLAIN CASTING GA8716 GA8716 GA8716

6 1 T4 INNER SHUTTER GA15126 GA15126 GA17210

7 1 T4 OUTER SHUTTER GA15127 GA15127 GA17290

8A 1 T4 SILENCER GA8891 GA8891 GA8892

8B 1 T4 CHAMFERED SNORKEL SILENCER GA21875 GA21875 GA21504

9 4 MOD PLATE SPACER GA7961 GA7961 GA7961

10 1 T4 MOD PLATE GA17188 GA17188 GA17188

11 1 RATIOTRONIC 6027 SERVO MOTOR ETCRAT00745 ETCRAT00745 ETCRAT00745

12 1 CABINET HANGER PLATE GA9093 GA9093 GA9093

13 1 CP552 UNIVERSAL HANDED BURNER

CABINET GA19714 GA19714 GA19714

14 1 CP552 CABINET DOOR GA10722 GA10722 GA10722

15 1 1/4" x 10mm SWIVEL ELBOW COMPAD00505 COMPAD00505 COMPAD00505

16 - n10MM BUNDI TUBE BUNDIT00090 BUNDIT00090 BUNDIT00090

17 1 1/4" BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD00485 COMPAD00485

18 1 LGW50 A2P PRESSURE SWITCH PRESWI00245 PRESWI00245 PRESWI00245

19 1 DN80 GASKET GASKET00970 GASKET00970 GASKET00970

20 1 QRA2 UV CELL AND BRACKET 12041 12041 12041

21 1 FAN HUB FOR T4 BURNER GA8767 GA8767 GA8767

22 1 T4 BOILER MOUNTING GASKET GA11741 GA11742 GA11742

23 1 T4 MULTI-FLAME MOUNTING SECTION GA20040 GA20134 GA20134

24 1 T415 - 420 MULTI-FLAME MOUNTING

SECTION NOSE CONE GA20042 GA20135 GA20135

25 1 T4 AIR GUIDE VANE (WHEN FITTED) GA22534 GA22534 GA22534

26 3 T4 MULTI-FLAME SPLIT BLOCK GA19506B GA19506B GA19506B

27 22 1/8" BSP DOWTY SEAL SEADOW00050 SEADOW00050 SEADOW00050


29 - n6mm BUNDI TUBE BUNDIT00070 BUNDIT00070 BUNDIT00070

30 8 1/8" BSP NON - RETURN VALVE VALVCH00220 VALVCH00220 VALVCH00220

31 8 1/8" BSP x 6mm STANDPIPE ADAPTOR COMPAD00280 COMPAD00280 COMPAD00280

32 3 ART106 BURNER GUN NOZZLE BLOCK

ASSEMBLY - OUTER NOZZLE GA20137 GA20137 GA20137

33 1 T4 MULTI-PIPE HEAD GA22262 GA20136 GA20136

34 3 M5 FLAT COPPER WASHER COPWAS00025 COPWAS00025 COPWAS00025

35 1 OIL SHELL HEAD FOR MULTI-OIL DUAL FUEL

BURNERS GA22263 GA18784 GA18784

36 1 TD4 MULTI-OIL MULTI-GAS FLAMEPLATE GA22662 GA22196 GA22196

37 4 ELECTRODE SPLIT BUSH GA8264 GA8264 GA8264

38 2 GAS IGNITION ELECTRODES IGELEC00100 IGELEC00100 IGELEC00100

39 2 ORING, BS206 VITON ORINGS00180 ORINGS00180 ORINGS00180

40 1 ORING VITON 0695-30 ORINGS01025 ORINGS01025 ORINGS01025

41 1 T3-T5 OIL BURNER SANDWICH BLOCK -

PART A GA9178A GA9178A GA9178A

42 1 T3-T5 OIL BURNER SANDWICH BLOCK -

PART B GA9178B GA9178B GA9178B


44 4 MOD PLATE SPACERS GA7961 GA7961 GA7961



45 1 PUMP MOTOR MOUNTING BRACKET GA9562 GA9562 GA9562

46 1 PUMP MOTOR MOTPUM00220 MOTPUM00220 MOTPUM00300

47 1 PUMP MOTOR HOUSING GA5900 GA5900 GA9740

48 1 DH PUMP VALVE BRACKET GA10190 GA10190 GA10228

49 1 DH OIL PUMP SERIES PUMDUN01021 PUMDUN01021 PUMDUN02015

50 2 No.3 BANJO BOLT GA10125 GA10125 GA10125

51 1 No.1 BANJO MANIFOLD BLOCK GA16777 GA16777 GA16777


53 2 1/2" BSP N/C LUCIFER OIL VALVE SOLOIL00240 SOLOIL00240 SOLOIL00240

54 5 1/2" BSP x 10mm MALE STUD COUPLING - - COMPAD00300

1/4" BSP x 10mm MALE STUD COUPLING COMPAD00485 COMPAD00485 -

55 1 1/4" BSP YORKSHIRE FITTING YORFIT00510 YORFIT00510 YORFIT00510

56 1 MANIFOLD BANJO BLOCK GA16780 GA16780 GA16771

57 1 MANIFOLD BANJO BOLT A GA10382 GA10382 GA10400

58 1 MANIFOLD BANJO BOLT B GA10143 GA10143 GA10401




62 2 1/2" BSP SRV OIL SOLENOID VALVE SOLOIL00360 SOLOIL00360 SOLOIL00360

63 8 10mm EQUAL TEE PIECE COMPAD00520 COMPAD00520 COMPAD00520

64 1 10mm EQUAL ELBOW COMPAD00435 COMPAD00435 COMPAD00435

65 2 VT2 METERING VALVE ASSEMBLY GA16090 GA16090 GA16090

66 2 RATIOTRONIC 6026 SERVO MOTOR ETCRAT00720 ETCRAT00720 ETCRAT00720

67 1 TWIN VT2 METERING VALVE MOUNTING

BRACKET OILMET00753 OILMET00753 OILMET00753




71 3 1/4" BSP MINI OIL BALL VALVE VALOIL00110 VALOIL00110 VALOIL00110

72 3 0 - 41 BAR (0-600 PSI) PRESSURE GAUGE PRESGA00155 PRESGA00155 PRESGA00155

73 2 PRESSURE SWITCH ADAPTOR (1/4" BSP - 1/2"

BSP REDUCER) BANMAN00170 BANMAN00170 BANMAN00170

74 1 HIGH OIL PRESSURE SWITCH (SAUTER)

HIGH OIL PRESSURE SWITCH (BAILEY)

PRESWI00570

PRESWI00700

PRESWI00570

PRESWI00700

PRESWI00570

PRESWI00700


76 1 DH OIL PUMP MOUNTING FLANGE - - PUMFLA00120


78 1 3/4" BSP x 1" BSP REDUCING NIPPLE - - PIPNIP01450

1/2" BSP x 3/4" BSP REDUCING NIPPLE PIPNIP01430 PIPNIP01430 -

79 1 3/4" BSP x 1" BSP POSITIONABLE ELBOW - - CONELB00135

1/2" BSP x 3/4" BSP POSITIONABLE ELBOW CONELB00125 CONELB00125 -

80 1 1/2" COPPER WASHER COPWAS00110 COPWAS00110 COPWAS00110


82 3 NYLON ROLLER GA5761A GA5761A GA5761A

83 3 STEEL BUSH FOR NYLON ROLLER GA5761B GA5761B GA5761B

84 1 BRIDGE HANDLE CONTOL02285 CONTOL02285 CONTOL02285

85 1 PUMP COUPLING & INSERT ASSEMBLY

(CHALLENGE) PUMZCP00665 PUMZCP00665 PUMZCP00665

86 1 COVER PLATE FOR PUMP HOUSING GA6707 GA6707 GA6707

87 1 10mm DIAMETER BUNDI TUBE GA23697A GA23697A GA23697A

88 1 10mm DIAMETER BUNDI TUBE GA23697B GA23697B GA23697B



89 1 10mm DIAMETER BUNDI TUBE GA23697C GA23697C GA23697C

90 2 10mm DIAMETER BUNDI TUBE GA23697D GA23697D GA23697D

91 1 16mm EYEBOLT EYEBLT00100 EYEBLT00100 EYEBLT00100


93 1 SWIVEL RUN TEE COMPAD00655 COMPAD00655 COMPAD00655

94 1 LOW OIL PRESSURE SWITCH (SAUTER)LOW

OIL PRESSURE SWITCH (BAILEY)

PRESWI00400

PRESWI00705

PRESWI00400

PRESWI00705

PRESWI00400

PRESWI00705

95 1 T4 GAS SIDE ENTRY PLATE PLCSIDENT00120 PLCSIDENT00120 PLCSIDENT00120

96 1 DN80 BUTTERFLY VALVE WITH BERGER LAHR

SERVO MOTOR GA17187 GA17187 GA17187

97A 1

T4 DN65 UNIBLOC ASSEMBLY



GA23518A

GA23518B

GA23518C

GA23518A

GA23518B

GA23518C

GA23518A

GA23518B

GA23518C

97B 1

T4 DN65 VG4.40 ASSEMBLY



GA23529A

GA23529B

GA23529C

GA23529A

GA23529B

GA23529C

GA23529A

GA23529B

GA23529C

98 1 ART106 NOZZLE BLOCK HOLDER GA09150A GA09150A GA09150A

99 1 TWIN OIL IGNITION ELECTRODE IGELEC00130 IGELEC00130 IGELEC00130

100 1 T4 MULTI-PIPE HEAD GA22262 GA20136 GA20136

101 6 T4 MULTI-PIPE GAS NOZZLE GA23522 GA23522 GA23522

102 1 DOUBLE BLOCK ELECTRODE HOLDER GA11883 GA11883 GA11883



11.5 TD410 Low NOx Combustion Head Assembly

11.6 TD415-420 Low NOx Combustion Head Assembly



11.7 TD410 Combustion Head Assembly

11.8 TD415-420 Combustion Head Assembly



11.9 DN65 Unibloc

11.10 DN80 Unibloc

11.11 DN100 Unibloc



11.12 VGD40.65 Assembly for Pneumatic Modulating and High Low Burners





11.15 VGD40.65 Assembly for Electronic Modulating Burners







12 Component Information

12.1 LFL1.333 Burner Control Box

To avoid injury to persons, damage to property or

the environment, the following warning notes

should be observed!

Do not open, interfere with or modify the unit!

Before performing any wiring changes in the connection

area of the LFL1…, completely

isolate the unit from the mains supply (all-polar disconnection)

Ensure protection against electric shock hazard by providing adequate protection for the

burner control’s connection terminals

Check to ensure that wiring is in an orderly state and that the wires are firmly connected

(refer to «Commissioning notes»)

Press the lockout reset button only manually (applying a force of no more than 10 N),

without using any tools or pointed objects.

Do not press the lockout reset button on the unit or the remote lockout reset button for

more than 10 seconds since this damages the lockout relay in the unit

Fall or shock can adversely affect the safety functions. Such units may not be put into

operation, even if they do not exhibit any damage.

In the case of flame supervision with UV detectors QRA..., it should be noted that sources

of radiation such as halogen lamps, welding equipment, special lamps, ignition sparks, as

well as X-rays and gamma radiation, can produce erroneous flame signals.

Mounting notes

Ensure that the relevant national safety regulations are observed.

When using 2 UV detectors QRA..., make certain that the detectors cannot see one another

Installation notes

Installation work must be carried out by qualified staff.

Always run the high-voltage ignition cables separately while observing the greatest possible

distance to the unit and to other cables.

Do not mix up live and neutral conductors

Electrical connection of ionization probe and flame detector

It is important to achieve practically disturbance and loss-free signal transmission:

Never run the detector cable together with other cables.

Line capacitance reduces the magnitude of the flame signal.

Use a separate cable of low capacitance

Observe the maximum permissible detector cable lengths (refer to «Technical data»)

2 UV detectors QRA... can be connected in parallel.

The ionization probe is not protected against electric shock hazard.

Locate the ignition electrode and ionization probe such that the ignition spark cannot arc

over to the ionization probe (risk of electrical overloads).

In connection with the QRA..., earthing of terminal 22 is mandatory.

Supervision with both ionization probe and UV detector QRA... is possible, but for safety

reasons – with the exception of the second safety time «t9» – only one flame detector may

be active at a time. At the end of the second safety time, one of the detectors must be

inactive, however, that is, the detected flame must have extinguished, e.g. by switching off

the ignition valve at terminal 17.



Flame supervision with ionisation probe

Voltage at the ionization probe:

Operation: AC 330 V ±10 %

Test: AC 380 V ±10 %

Short-circuit current max: 0.5 mA

Required ionization current min: 6 µA

Recommended range of measuring

instrument: 0...50 µA

Perm. length of detector cable:

Normal cable, laid separately.

(multicore cable not allowed) max. 80 m

Shielded cable: max. 140 m (e.g.

high-frequency cable, shield connected

to terminal 22

Flame supervision with QRA…

Supply voltage:

Operation: AC 330 V ±10 %

Test: AC 380 V ±10 %

Required detector current min: 70 µA

Possible detector current:

Operation: max. 680 µA

Test: max. 1000 µA ¹)

Perm. length of detector cable:

Normal cable, laid separately

(Multicore cable not permitted): max. 100m

Shielded cable: max. 200 m (e.g. high-frequency cable,

shield connected to terminal 22)

Note1) During the pre-purge time with higher test voltage: self-ignition and extraneous light test



LFL Technical Data



LFL Characteristics

Mains voltage AC 230 V –15 / +10 %

AC 100 V –15 %...AC 110 V +10 %

Mains frequency 50...60 Hz ±6 %

Unit fuse (built-in) T6,3H250V to DIN EN 60 127

Primary fuse (external) max. 10 A (slow)

Power consumption approx. AC 3,5 VA

Perm. input current at terminal 1 max. 5 A continuously, peaks up to 20 A for 20 ms

Perm. load on control terminals 3, 6, 7,

9...11, 15...20 max. 4 A continuously, peaks up to 20 A for max. 20

ms, total max. 5 A

Required switching capacity of switching

devices 1 A, AC 250 V

- Between terminals 4 and 5 1 A, AC 250 V

- Between terminals 4 and 12 min. 1 A, AC 250 V

- Between terminals 4 and 14 depending on the load on terminals 16...19

LFL Operation



General

Detector and extraneous light test are resumed immediately on completion afterburn time

«t13». Fuel valves that are not closed, or not fully closed, immediately initiate lockout on

completion of the afterburn time «t13». The test terminated when the prepurge time «t1» of

the next startup sequence.

The proper functioning of the flame supervision circuit is automatically during each startup

phase of the burner

During the postpurge time «t6», the control contacts for the release checked to ensure they

have not welded.

The built-in unit fuse protects the control contacts against overloads.

Preconditions for start up

Burner control must be reset

Sequence switch must be in its start position - voltage at terminals 4 and 11 present and air

damper closed

End switch «z» for the CLOSED position must feed voltage from terminal 11 to terminal 8

The contacts of control thermostat or pressurestat «W» and other contacts of switching

devices connected between terminal 12 and «LP» must be closed _ e.g. control contact for

the oil preheater’s temperature.

Terminal 4 must be live

The N.C. contact of the air pressure switch must be closed - «LP» test

Start up sequence

A Start command (delivered by «R» for instance)

A-B Startup sequence

B Operating position of the burner

B-C Burner operation (according to the control commands delivered by «R»)

C Controlled shutdown via «R»

C-D Sequence switch travels to start position «A», postpurging

During burner off periods, only control outputs 11 and 12 carry voltage and the air

damper is in its CLOSED position as defined by end switch «z» of the actuator.

Also, in order to perform the detector and extraneous light test, the flame supervision

circuit is live (terminals 22 / 23 and 22 / 24).

A Start command delivered by «R»

→ «R» closes the start control loop between terminals 4 and 5

- The sequence switch starts running

- Only prepurging, power is immediately fed to the fan motor

connected to terminal 6

- Pre and postpurging; on completion of «t7», power is fed to the fan

motor or flue gas fan connected to terminal 7

- On completion of «t16», the control command to open the air damper is

delivered via terminal 9

- No power is fed to terminal 8 during the positioning time

- The sequence switch continues its travel only after the air damper has fully

opened.

t1 Prepurge time with air damper fully open

- During «t1», the correct functioning of the flame supervision circuit is

tested

- If test is not successful, the burner control will initiate lockout



Shortly after the start of «t1», the air pressure switch must change over from

terminal 13 to terminal 14.

- Otherwise lockout

- Start of air pressure check

At the same time, terminal 14 must be live since the ignition transformer will be

powered and the fuel released via this current path.

On completion of the prepurge time, the burner control will drive the air damper

to the low-fire position via terminal 10, which is determined by the changeover

point of auxiliary switch «m». During the positioning time, the sequence switch

stops again. A short time later, the motor of the sequence switch will be

switched to the control section of the burner control. This means that, from now

on, positioning signals delivered to terminal 8 have no impact on the burner’s

further startup sequence (and on subsequent burner operation):

t5 Interval

- On completion of «t5», power is fed to terminal 20; at the same time, control

outputs 9...11 and input 8 are galvanically separated from the unit’s control

section.

- The LFL1... is now protected against return voltages from the power

control loop.

- The startup sequence of the LFL1… ends with the release of «LR» at terminal 20

- After a number of idle steps (steps with no change of the contact position), the

sequence switch switches itself off

Expanding flame burners

TSA Ignition safety time

On completion of «TSA», a flame signal must be present at terminal 22. It must not

be interrupted until controlled shutdown takes place

- otherwise lockout

t3 Pre-ignition time

Release of fuel via terminal 18

t4 Interval «BV1 – BV2» or «BV1 - LR»

- On completion of «t4», terminal 19 is live

- That powers «BV2» connected to the actuator’s auxiliary switch «v»

Control sequence under fault conditions and lockout indication

In the event of any kind of fault, the sequence switch will stop and, with it, the lockout indicator.

The symbol above the indicator’s reading mark gives the type of fault:



If lockout occurs, the burner control can immediately be reset:

- Do not press the lockout reset button for more than 10 seconds

The sequence switch always returns to its start position first

- After resetting

- After correction of a fault which resulted in plant shutdown

- After each power failure

During that period of time, power is only fed to terminals 7 and 9...11.

Then, the LFL1... begins with a new burner startup sequence.



LFL Glossary of symbols



12.2 RWF 40 Burner temperature controller

The RWF40 is used to control the boiler temperature.

It is configured to modulate the burner up and down when firing on gas

and provide high/low thermostat functions when firing on oil.

In modulating operation the RWF40 operates as a PID controller. In 2-

stage operation the RWF40 provides control based on the set switching

threshold. The setpoint of the RWF40 can be adjusted either on the

controller itself or externally.











12.3 Unibloc

12.3.1 Unibloc General Arrangements

All Unibloc gas trains are manufactured and tested in accordance with EN 161 : 1991 'Automatic

Shut-off Valves for Gas Burners and Gas Appliances'

The Unibloc body is cast iron to BS 1452 grade 220 (the 100 N.B. body conforming to EN161 is

S.G. cast iron to BS 2789 grade 2712). All bodies are manufactured in one piece and are precision

machined to accept the various gas valve actuators that are described in section 2.

The standard unit is designed for use with 2nd and 3rd family gases and is fitted with plated carbon

steel valve seating rings. For other gas applications, e.g. bio or producer gas, the valve seating rings

are manufactured out of grade 321 stainless steel, because of the corrosive nature of these gases.

Where hydrogen sulphide (H2 S) is present in the gas advice must be sought from Dunphy

Technical Department.

A gas filter is fitted around the seating of the first stage valve to prevent foreign bodies entering the

Unibloc and causing valve seating problems. Gas filters are available to suit the various

specifications as required.



Valve actuators are supplied as standard with plated carbon steel seat assemblies fitted with nitrile

rubber seating discs.

If valves are required to be used on bio, producer or other corrosive gases, the valve seat assemblies

will be manufactured in 321 stainless steel with viton seating discs.

Installation

Select a location where the ambient temperature will be within the range of 0°C to +50°C, ensure

that the gas supply pipework is clean and contains no loose particles, fit valve to pipework so that

the gas flow travels in the direction of the arrows on the valve casing.

Please note that the 40, 50, 65, 80 and 100 mm N.B. valve bodies should be mounted with the inlet

flange facing vertically downwards. The 125 mm. N.B. valve body has an adjustable inlet flange

section that can be rotated to face in various directions

Due to the size and weight of the 100mm N.B. Unibloc, it is recommended that after installation

in the gas pipework the valve body is supported using the hole drilled in the valve body rib.



12.3.2 65mm Ratiotronic Unibloc exploded diagram and parts list.



12.3.3 65mm Ratiotronic Unibloc with pilot exploded diagrams and parts list





12.3.4 80mm Ratiotronic Unibloc exploded diagrams and parts list








12.3.6 100mm Ratiotronic Unibloc exploded diagrams and parts list








12.4 Butterfly Gas Valve

12.4.1 General Arrangement



12.4.2 Exploded Diagram



VGD20

VGD40

12.5 Siemens VGD20 and VGD40 Gas Valve Blocks

Double gas valves for use on gas trains, consisting of 2 class «A»

safety shutoff valves.

Suited for use in connection with gases of the gas families I...III.

The double gas valve is to be combined with 2 actuators of the

SKP… series (e.g. to provide the functions of 2 safety shutoff

valves connected in series, with different types of gas pressure

governor if required).

Supplementary data sheets on the actuators is located at the end

of this section.

To avoid injury to persons, damage to property

or the environment, the following warning notes

should be observed!

Do not open, interfere with or modify the double gas valve,

except when fitting the service replacement set! _ When used in

connection with gas, the valves constitute part of the entire safety

system. Fall or shock can adversely affect the safety functions.

Such valves may not be put into operation, even if they do not

exhibit any damage.

Protect the actuator against excessive temperatures (caused by radiation, for example), to ensure the

maximum permissible ambient temperatures will not be exceeded.

Mounting notes

Ensure that the relevant national safety regulations are complied with. To mount the double gas

valve VGD20..., 2 flanges type AGA41... / AGA51... are required.

To prevent cuttings from falling inside the valve, first mount the flanges to the piping and then

clean the associated parts. On the gas train, the valve can be mounted in any position, but the

permissible mounting positions of the associated actuator must be observed (refer to the relevant

Data Sheet)

The direction of gas flow must be in accordance with the arrow on the valve body.

When used in combination with the SKP10..., SKP15..., SKP25... or SKP75...,

the minimum gas pressure switch must always be mounted upstream of the double gas valve!

The electro hydraulic SKP15... actuator, which is used for shutoff functions, must always be

mounted on the inlet side while the actuators with integrated governor (SKP25..., SKP75...,) must

always be fitted on the outlet side of the valve (with a contoured disk).

Check to ensure the bolts on the flanges are properly tightened . Check to ensure the connections

with all components are tight. Mounting and replacement of the actuator can take place while the

valve is under pressure. Sealing materials are not required. Ensure that the O-rings are fitted

between the flanges and the valve body.

Installation notes

Installation work must be carried out by qualified staff.

If the available gas pressure exceeds the valve’s maximum permissible operating pressure, the gas

pressure must be reduced by a pressure regulator upstream of the valve.



Commissioning notes

Commissioning work must be carried out by qualified staff.

If environmental conditions produce corrosion (e.g. sea climate), apply protective coating.

Check wiring carefully prior to commissioning.

Standards

CE conformity in accordance with the directives of the European Union

- Directive for pressure equipment 97/23 EEC

- Directive for gas appliances 90/396 EEC

Service notes

Check the correct functioning and the internal and external tightness of the VGD... each time a

valve has been replaced. The valve may only be replaced by qualified staff.

VGD20

The double gas valves VGD20... are of the normally closed type and have 2 disks, one non-

contoured disk on the inlet side and one contoured disk on the outlet side. The stems are guided on

both sides of the disks, thus ensuring precise alignment and tight shutoff. The high closing force of

the return spring is supported by the prevailing gas pressure (class «A» to EN 161). A strainer on

the inlet side protects the valve and downstream controls against dirt. Valve body and connecting

flanges are made of die-cast aluminium, the seals of nitril rubber, and the stems of stainless steel.

The double gas valves feature a pilot gas connection Rp¾" . Gas valve, flanges and actuators are

supplied as separate

items. The 4 screws

required to fit the SKP...

to the valve are contained

in the terminal

compartment. No special

tools are required for

assembly. The

connecting flanges have

a test point. They are

internally threaded and

supplied as separate

items, together with the

necessary accessories, such as bolts, nuts, seals, etc. The overall flange dimensions and bore-holes

are identical, so that all types of flanges can be fitted to the double gas valve, irrespective of

nominal size. This means that a 1½" flange can be fitted to a 2" VGD... valve, and vice versa. Each

double gas valve requires 2 connecting flanges, which are to be ordered as separate items.

General Data

Class A (EN 161)

Group 2 (EN 161)

Types of gases gas families I, II, III (to G260 of DVGW) air

Built-in strainer, mesh size 0.9 mm

Perm. medium temperature -15...+60 °C

Mounting spring housing horizontal or vertical, pointing downward

Flanges for VGD40... to ISO 7005; PN16

Materials

- VGD20... die-cast aluminium

- VGD40... sand-cast aluminium



VGD40

The double gas valves VGD40... are double seat disk valves of the normally closed type. The stems

are guided on both sides of the disks, thus ensuring a precise stroke and tight shutoff. To improve

the control performance, the disks at the bottom are pro-filed.

The patented double seats are closed by 2 springs. The high closing force of the return spring is

supported by the prevailing gas pressure (class «A» to EN 161). The spring of each stem exerts a

pressure on the disk so that there is a

defined closing force acting on each disk.

The surface area proportions of the 2 valve

disks per stem

are such that the closing force increases as

the inlet pressure increases (class «A» valve

to EN 161). A strainer on the inlet side

protects the valve and downstream controls

against dirt. The 4 screws required to fit the

SKP... to the valve are contained in the

terminal compartment. The double gas

valves DN40…150 correspond to the

standard valve sizes of single valves (EN

558).

The VGD40... are supplied with a pilot gas

flange having a ¾“ connection for the pilot

gas line and a ¼“ connection for an impulse line. This impulse line connection between the 2 valves

and another impulse line connection on the outlet flange can be connected directly to the constant

pressure governor SKP20... fitted to «V1» or «V2».

A universal mounting plate facilitates attachment of a number of commercially available pressure

switches or valves proving devices. Both the pilot gas flange and the universal mounting plate are

exchangeable and can be fitted on either side of the valve.



Power Output Curves



12.5.1 Siemens SKP actuators

The combination of actuator and valve provides the following functions:

- Safety shutoff valve (SKP15...)

- Safety shutoff valve with gas pressure governor / controller (SKP25..., SKP55..., and SKP75...)

The electrohydraulic SKP... actuators together with the valves are designed for use with gases of

gas families I...III and air. They are used primarily on gas-fired combustion plant. The actuators

open slowly and close rapidly. They can be combined with any of the above mentioned valve types

and nominal sizes. The actuator can be supplied with end switch (for indicating the fully closed

position).

The SKP25... operates as a constant pressure governor with a setpoint spring.

Its field of use are primarily forced draft gas burners

- with mechanical fuel / air ratio control

- with electronic fuel / air ratio control

The SKP55... operates as a differential pressure

governor. Its field of use are primarily

- combustion plant with combined heat recovery

systems

- plant where pressure conditions in the burner and

in the combustion chamber do not change in

proportion to load changes - burners with adjustable

fuel / air mixing devices in the burner head - plant

with negative pressure levels on the gas or air side.

The SKP75... operates as a ratio controller and

provides control of the gas pressure

depending on the pressure of the combustion air,

ensuring that the gas / air ratio remains

constant across the entire load range. Its field of use are primarily modulating forced draft gas

burners.

To prevent injury to persons, damage to property or the environment, the following warning notes

should be observed! Do not open, interfere with or modify the actuators!



• All activities (mounting, installation and service work, etc.) must be performed by qualified staff

• Check to ensure that the impulse pipes are properly fitted and tight

• Fall or shock can adversely affect the safety functions. Such actuators must not be put into

operation, even if they do not exhibit any damage.

• If mains voltage is fed to the end switch via the second plug-in space, protective earth must be

connected to the actuator via the same plug.

• Use of connectors conforming to DIN EN 175301-803-A is mandatory

• The connectors used must have cable strain relief

• The pump’s stem must not be pulled out using the overstroke element since that part could

become loose.

If the available gas pressure exceeds the maximum permissible operating pressure of the valve /

SKP..., it must be lowered by an upstream pressure controller. The pressure switch for lack of gas

must always be fitted upstream of the gas valve when used in connection with the SKP… The

inside diameter of the impulse pipes must be a minimum of 6 mm. The impulse pipes must be

installed such that the differential pressure can be acquired with no disturbance (unfavourable flow

conditions). Pressure test points must not protrude and be flush with the inside diameter of the pipe

or duct wall. The impulse lines to the governor / controller should be as short as possible, enabling

the governor / controller to respond quickly should sudden load changes occur.

• Installation of impulse pipes

In the case of unsafe combustion chamber pressure pipes (e.g. resulting from potential leaks), the

setting must also be checked during operation without having the combustion chamber pipe

connected, especially with respect to maximum burner capacity. The impulse pipes must be fitted

such that the differential pressure can be acquired with no disturbance. With gas / air ratios > 3, the



impulse pipes for the combustion air and the combustion chamber pressure must have an inside

diameter of at least 8 mm. The impulse pipe for the combustion chamber pressure must be fitted

such that the gases will cool down in the vicinity of the impulse pipe and condensing gases cannot

enter the controller but will return to the combustion chamber.

Recommendations:

– The gas pressure should be acquired at a distance of 5 times the nominal pipe size downstream

from the valve.

– Do not use the lateral test points on the VG... valve body for picking up the pressure

• Considering the combustion chamber pressure

If the resistance value of the combustion chamber / heat exchanger / stack system is constant, the

combustion chamber pressure changes in proportion to the gas and combustion air pressure as the

burner’s output changes. In that case, the combustion chamber pressure need not be fed to the

SKP75... as a disturbance variable. However, if the combustion chamber pressure does not change

to the same extent as the gas and air pressure – as this is the case in plants with flue gas fan or

modulating flue gas damper – the combustion chamber pressure must be fed to the SKP75... as a

disturbance variable, enabling the controller to counteract.

• Ensure that the relevant national safety regulations are complied with

• The quadratic arrangement of the fixing holes allows the actuator to be fitted in 4 different

positions, each step being 90°

• The actuator can be mounted or replaced while the system is under pressure; sealing

materials are not required

• Electrical commissioning may only be performed when the SKP… is fitted to the valve;

otherwise, the SKP… can be damaged.

• Power is supplied and connection of the end switch is made directly via a connecting cable

(conforming to DIN EN 175301-803-A)

• The end switch is factory set.

When power is applied, the pump will be activated and the control valve closed. Oil is now pumped

from the chamber below the piston to the pressure chamber above the piston. The oil pressure

causes the piston to move downward, thereby opening the valve – against the pressure of the

closing spring. The pump remains energized until the closing command is given. When power is

removed, or in the event of a power failure, the pump will be deactivated and the control valve

opened so that the closing spring pushes the piston back. The return flow system is sized such that

the counterstroke required for reaching the fully closed position is completed within about 0.6

seconds.









12.6 VPS 504 Valve Proving System

The VPS 504 is the valve proving system used for double

block gas valves. The valve proving system complies

with EN 1643:

Equipment operates independent of residual

pressure in the range of the permissible operating

range

Test volume ≤ 4 l

Setting work not necessary on site

Short test period: min. 10 s, max. 26 s

Tightness or leaks are displayed by an LED

External fault display possible for series 02, series

04 and series 05.

Group fault alarm optional for series 01 (SSM)

Suitable for TRD systems

Electrical connection possible by plug connection

series 01, 02, 03. No rewiring is required for

contact allocation as per DIN 4791.

Series 04 and series 05: electrical connection at screw terminals via PG 13.5 cable entry.

Suitable for gases of gas families 1, 2, 3 and other neutral gaseous media.

Not suitable for use with hydrogen – VDK 200 H2 to be used for hydrogen.

Approvals

EC type test approval as per EC Gas Appliance Directive: VPS 504… CE-0085 AP 0168

EC type test approval as per EC Pressure Equipment Directive: VPS 504… CE0036

1 Hall switch

2 Solenoid

3 Pressure switch diaphragms

4 Compression spring

5 Filter

6 Solenoid valve anchor

7 Solenoid valve coil

8 Pressure pump

9 Unlock switch

10 Fault lamp

11 Operating lamp

12 Test nipple

13 Volume restrictor

14 Pump diaphragm

15 Pump linkage

16 PCB

17 Plug connection

18 Equipment fuse

19 Spare fuse



Specifications

Operating pressure max. 500 mbar (50 kPa)

Test volume 4.0 l

Pressure increase by motor pump 20 mbar

Nominal voltage (Permissible voltage range)

230 V AC (-15%) to -240 V (+6%), VPS 504 series 05: 24 VDC For further voltages, refer to type overview

Frequency VPS series 01-04: 50 Hz or 60 Hz Series 05: DC

Rating requirement During pumping time approx. 6 VA, in operation 17 VA

Prefuse (provided by customer) 10 A quick-acting or 6.3 A slow-acting fuse

Fuse installed in housing cover, replaceable

Microfuse 6.3 slow-blow L 250 V; IEC-127-2/III (DIN 41 662)

Switching current Operating output VPS 504 Series 01, 02, 03, 04, 05: max. 4 A Interference output VPS 504 Series 02, 04, 05: max.1A Refer to motor startup current!

Degree of protection VPS 504 Series 01, 02, 03: IP 40 VPS 504 Series 04, 05: IP 54

Ambient temperature 50 Hz 230 VAC -15°C to +70°C others: -15°C to +60°C

Release time Approx. 10 - 26 s, depending on test volume and input pressure

Sensitivity limit max. 50 l/h At inlet pressures of < 50 mbar, limit pressure rates well below 50 l of air per hour occur due to the mode of operation. This allows for applications involving low inlet pressures.

Switch-on duration of control 100 % ED

Max. number of test cycles 20/h. Wait for at least 2 minutes after carrying out more than 3 consecutive test cycles.

Installation position vertical, horizontal, not upside down

Media • Standard model • Liquefied gas model

Gas families 1, 2, 3 and other gaseous media. Not suitable for butane. Gas family 3 and butane

The VPS 504 operates depending on pressure

build-up.

The program module starts to function when

heat is requested.

Test is performed depending on the

burner functional procedure:

Check prior to burner start or

Check during pre-purge period or

Check after burner shut-down



Electrical Connections



12.7 Variotronic VT Oil Metering Valve

12.7.1 General Description

The Variotronic oil valve has been designed to work primarily in conjunction with electronic

positioning motors for the accurate control of fluids, fuel oils and liquids as defined in the

specification of recommended applications.

The design of the valve incorporates an adjustable linear characterising spool which enables the

valve to operate to a virtually linear characteristic. the characterising spool adjusts the output of the

valve in relation to the metering valve spindle. This changes the flow rate of the valve - thus

ensuring that the maximum angular rotation is utilised to optimise the flow accurately.

12.7.2 Construction

The valve construction consists of a carbon steel body which is

drilled at each end to accommodate the valve output port and the

valve retaining cap. The output port is secured by 6 screws with an

oil seal 'O' ring sealing the face of the end cap and valve body. An

identical construction is on the drive end of the valve.

The end cap has a duel function in retaining the spool sleeve and

providing a clamp for adjustment. The valve control flow spindle is

mounted directly through the spool and retained by the output port

plate. This also has a duel function acting as a surface thrust plate

for the valve control. When the valve is used in conjunction with an

electronic servo motor, there are mounting pillar locations provided

at 52mm hole centres (which is the European standard for the 4Nm

required torque for operating this type of valve.)

12.7.3 Valve Maintenance

All rotating valves do eventually require maintenance, but maintenance is only generally necessary

as a result of wear on oil seals or 'O' rings. as a general guide we recommend that 'O' rings are

normally re-placed every 2 years or 20,000 hours, but this could vary on the type of fuel being

used, generally when operating on heavy fuel oils the service frequency should be reduced to 12

months. The normal grade of 'O' ring seals fitted within the valve is Viton.

Special materials are available for corrosive or fuels that contain corrosive substances. The

general service and maintenance of the valve is a very simple operation and all the seals could be

changed within a matter of minutes. It is essential to ensure that all replacement seals are of the

correct specification, any deviation from the specification could lead to premature seal failure and

even leakage from either the valve spindle or retaining faces.

12.7.4 Changing Seals

It is recommended that a spare set of seals is always retained for service and maintenance of the

valve. Changing the seals is a relatively simple task.

A. Isolate all electrical and fuel supplies

B. Ensure that the valve is cold and that there is zero pressure within the hydraulic circuit

C. Disconnect the valve drain mechanism, either mechanically or via electric servomotor

D. Before dismantling the valve, ensure that the positions are appropriately marked so that the

re-assembly, particularly of the spool ring can be repeated to the original settings. Remove

the 2 pillars securing the index plate. this will then expose the 4 countersunk retaining

screws on the valve retaining cap. The valve can then be de-assembled.



E. The entire metering spindle and spool sleeve can be removed from the top plate. The

spindle has a Viton 'O' ring and there is a Viton 'O' ring between the cap and the valve body.

the shaft sealing is via 2 x 'O' rings which are submersed inside the spool sleeve.

There should not be any need to remove the bottom plate, although as a precautionary measure if

'O' rings are being replaced, it is good practice to replace all of the seals with the correct

specification for the valve.

12.7.5 Adjustment of the valve

Since the valve can operate either for spill back

nozzles or for direct metering of fuel, the

configuration can be changed by indexing the

pool witness mark to change the opening and

closed characteristic of the valve. In other words,

when the witness plate is indexed to position 'A'

the valve operates from closed to open over the

90 degree scale.

When the witness plate is indexed to position

'B', the valve operates from fully open to closed over a 90 degree movement. It is also possible to

change the flow characteristic of the valve by changing the position of the spool in accordance with

the details on the flow graph and scale plate indicators.

Valve adjustment is extremely simple. The design of the valve allows maximum travel from 0 to

90 degrees to control the modulating range of the burner. Depending upon the flow rate required

across the valve, this could control fuel flows in excess of 20:1 over the valve spindle angular

movement.

It is possible to adjust the output of the valve whilst still maintaining the large amount of

linearization by adjusting the spool ring on the inner scale plate. This is adjusted by loosening the

retaining cap and rotating the spool with a peg spanner. The index mark on the spool indicates the

spool position which can be read in conjunction with the flow charts on the opposite page.

12.7.6 Installation of the valve

The Variotronic valve can be mounted in any access. it is however,

essential that there is no pipe stress from either the inlet or discharge

port of the valve. Any external pressure caused from pipe stress could

distort or cause the valve to malfunction. Fixing of the valve is via a

pad with 2 off tapped holes, 5MM tapped directly into the valve body.

12.7.7 Valve Drive

While the Variotronic valve has primarily been designed to be driven

by an electronic positioning motor, it is possible to use the valve via

mechanical linkage. It is essential that there is zero play on any

connection between the valve spindle and the drive to the valve. This

is particularly important with electronic positioning since the valve is

normally controlled by a sensor or potentiometer mounted directly on

the servo motor shaft.

Zero hysteresis drive couplings must be used or, alternatively, a solid

coupling between the servo motor and valve spindle. Before commencing operation of the valve,

please ensure that there is oil or lubrication within the valve.

Do not run the valve dry as this could affect the long term accuracy. If the valve has to be operated

before the oil system has been fully primed, it is prudent to put lubricating oil in the valve ports.



12.7.8 Exploded Diagram



12.8 DH Series Pump

`DH` SERIES GENERAL DESCRIPTION

The oil pump is a vital part of any oil fired heating plant, whether

being used as a transfer pump for pumping oil at low pressures or on

an oil burner delivering oil at 35 bar.

The Dunphy DH series pump has been specifically designed to

overcome the problems associated with current grades of fuel oils in a

variety of different situations, giving accurate pressure control

combined with reliability and performance.

The pump housing is Grade 14 cast iron that is precision machined to

accept the various combinations of gear sets that are available to suit a

wide variety of applications.

Exhaustive work on test rig and field trials that internal leakage’s in a

gear pump are most severe through the lateral running clearances.

They are less severe through the radial clearances, here, the leakage

path is long and the rotation of the gears opposes the pressure gradient.

Based on these observations a `Sandwich` construction of the gear-set

and the pumping chamber has been designed from first principles.

Calculations and computer modelling gave clear figures for the very

high bearing loads resulting from high liquid pressure acting on the

projected area of the gears. As a result, the design has catered for

bearings of large surface area. This must result in minimal rubbing

speed. They must also provide rigid shaft support with no appreciable

deflection.

The final design provides all DH series with gear-sets of nitrogen

hardened steel supported by an extremely strong bearing assembly.

It enables the standard unit to handle fuels with viscosities from 2 up to

2000 centistokes at pressures up to 35 bar and temperatures of up to

140ºC.

Single or tandem gear-sets can be offered as standard. Pumps with

special series gear-sets can be offered for specific applications.

The most characteristic and frequent failure of oil pumps is that of

pump seizure. In operation, a gear pump is required to deliver the

maximum possible volume for a given centre distance and face-width

of the gears. Losses due to internal leakage must be minimal and

sufficient only to provide adequate lubrication of the rotating parts.

However, the capacity of the gear-set depends on the depth of the gear

tooth. Design must therefore cater for a minimum number of teeth and

for minimum peripheral rubbing speeds

These parameters were used in making a choice between an internal

pinion and rotor format and an external gear-set employing straight

spur gear teeth of corrected involute form.

Dunphy engineers chose the external gear-set because it provides

maximum capacity for minimum peripheral rubbing speeds.

This factor is of vital importance in the elimination of pump seizure.



12.8.1 Pressure Regulation

A pressure regulating valve is provided as a

standard feature of the pump.

It is located within the pump body and

consists of a steel piston with P.T.F.E. wipers

that slides in a honed steel bore.

Pressure is exerted on the piston itself by a

spring, the loading of which is adjustable by

the user.

The pressure of the oil bears on the cross

sectional area of the piston.

When oil pressure and spring force balance,

the piston lifts and permits by-passed oil to

return to the suction port.

The accuracy of the machining and honing

ensures that the close fitting piston is kept in

contact with the cylinder bore by the pressure

of oil acting on its annular area

This combination of material selection and

fine tolerance eliminates edge filtration,

prevents sticking in operation and reduces

hysteresis effects to an absolute minimum.

The Dunphy DH Series of oil pumps has been

purposefully designed, in-house, to a

demanding brief, by experienced engineers

who have learned, at plant level, what

qualities the user demands of an oil pump.

As a result the DH oil pump has been

designed up to an extremely high quality

standard.

For heavy oil installations, the DH pump can

be fitted with a restrictor which will allow oil

from the ring main system to circulate

through the flexible oil lines and also the

pump body when the burner is not running.

This facility eliminates the need to insulate

the pump and the flexible's and ensures that

both are kept at the correct temperature.



VISCOSITY

70%

95%

VO

LU

ME

TR

IC

EF

FIC

IEN

CY

12.8.2 Technical Data Summary

Pump Model Code

DHO-1

DH1-1

DH1-2

DH2-1

DH2-2

Gearwheel Capacity litres/hr 290 750 1500 2250 4500

Gearwheel Capacity gall/hr 65 165 330 495 990

Weight - kg 6.3 6.7 8.1 17.5 20.9

Shaft Diameter - mm 10 10 10 16 16

Fuel Types 1.3 cSt. @ 40°C up to 130 cSt. @ 80°C

Speed 3600 Revolutions per minute ( maximum )

Operating Pressures 35 bar on standard units, maximum of 60 bar on tandem units

Capacity Range 145 to 4500 litres/hour ( 32 to 1000 imp gallons/hour approx )

Inlet Pressure 2 bar ( maximum ) ( 30 lbs. sq. inch )

Pump Fixing Flange or Boss

Maximum Operating Temperature ( Fuel Oil ) 140°C

NOTES

1. PUMP CAPACITY

A number of variants can be offered. There are

two basic gear-sets available in the range, these

cover swept volumes from 290 to 4500 litres/hour

at 2 pole ( 2850 rpm and 3400 rpm ) speed.

The further variants arise from the potential of

using the pumps as SINGLE, SERIES

or TANDEM sets as described in the diagrams

below.

SINGLE gear-set

The SERIES arrangement provides a similar CAPACITY

to the SINGLE but the PRESSURE can be doubled

without any increase on the bearing load.

The TANDEM arrangement DOUBLES the capacity

of the SINGLE gear-set

SINGLE

SERIES

TANDEM

2. CAPACITIES

Capacities are given for pumps running

at 2 pole speed ( 2850 rpm ) and a 50 Hz

electric supply.

3. GEARWHEEL CAPACITIES

As stated, these give the full swept

volume of the pump.

Because running clearances in the pump

are at an absolute minimum, the

Volumetric Efficiency of the gear-set

becomes a function of the viscosity of the

liquid being pumped.

( See diagram below ).



12.8.3 Installation Operation Maintenance

12.8.3.1 Installation

The DH Series can be supplied for either

flange or boss mounting to suit most

applications.

Pumps should be mounted with the shaft

horizontal, but the pump body may be turned

on its axis to allow easier access for pipe

connections etc.

It is essential that the pump and the motor

drive shafts are correctly aligned, that there is

no `play` in the drive connector and that there

is no end pressure on either drive shaft.

See the pump and motor arrangement

drawing at the bottom of the page.

Check that all joints on the oil supply pipes,

flexible oil lines etc. are properly sealed and

that the oil supply temperature and pressure

are correct ( see the relevant burner manual

for guidance notes on oil installation,

remembering that the maximum permissible

oil supply pressure to DH series pumps is 2

bar.

Residual fuel oils should be supplied to the

inlet port of oil burner pumps at temperatures

of:

40ºC for 200 secs R1 ( 13.5 cSt at 80ºC )

65ºC for 960 secs R1 ( 35 cSt at 80ºC )


When DH series pumps are used with

air/steam atomised burners burning residual

fuel oils the oil supply temperatures can be

reduced to:

10ºC for 200 secs R1 ( 13.5 cSt at 80ºC )



Distillate fuel oils should be supplied to the

pump inlet port at a slight positive pressure.

Where suction lift is required, the Dunphy

technical department should be consulted.

Residual fuel oils should be supplied to the

pump inlet port at a pressure between 1 and 2

bar.

12.8.3.2 Filtration

Filters must be fitted in the oil supply system

to prevent foreign matter entering the pumps

and possibly affecting performance or

causing physical damage.

All DH1 fuel are supplied with internal

filters, however, when pumps are used with

residual fuel oils, it is recommended that this

filter is removed after approximately one

weeks running when it is certain that any

swarf or other foreign matter has been

thoroughly flushed out of the oil supply lines.

DH2 pumps do not have an integral filter.

12.8.3.3 Oil Re-Circulation

When supplied for use on heavy oil

installations all `DH` series pumps are fitted

with a restrictor with a 4mm diameter orifice

fitted between the oil inlet and ring main

return ports.

This allows the flow of oil to circulate from

the ring main system, through the flexible oil

lines and pump and into the ring main return,

effectively keeping both the pump and the

flexible oil lines warm, eliminating the need

for lagging and trace heating.

The pumps can be fitted with restrictors with

a larger orifice size, but care must be taken

when fitting these that the re-circulation does

not depress the ring main capacity as this is a

direct bleed between the flow and return.

12.8.3.4 DH (P) Fuel Pumps ( Light oil)

All `DH` series pumps with the prefix `P` are

fitted with a manifold on the oil return port

that allows a flow of oil back into the return

while the burner is `purging`.

This allows the pump to automatically prime

itself every time the burner goes through its

starting cycle and eliminates the need for

mechanical venting.

P U M P

H OU S IN G C OV E RA N D S C R E W S

C OU P L IN G A N D S E T S C R E W SC OU P L IN G IN S E T

H OU S IN G

P U M P F L A N GE A D A P T ORA N D S C R E W S

P A R A L L E L K E Y D R IV E M O T OR

TYPICAL ARRANGEMENT OF PUMP, MOTOR AND DRIVE COUPLING



12.8.4 Fault Finding

Symptom or Fault Probable Cause

Pump motor runs, but no oil delivered. Pump coupling loose on either pump side or motor side.

Fuel starvation.

Oil system air locked.

Pump seized.

Pump shaft broken.

Pump rotates but no oil passing from nozzle. Burner solenoid valves not opening.

Blocked atomising nozzle.

Fuel starvation.

Pump noisy. Gas or air in pump

Pump worn.

Blocked line filters.

Insufficient pressure in pumped ring main to suppress

gas formation in the suction side of the pump.

Fluctuating Oil Pressures. Dirt in regulating valve.

High vacuum at pump suction.

Fuel starvation.

Worn pump.

Pump drive slipping.

Air leakage into the system.

Low Oil Pressures. Pump undersized.

Pump worn.

Defective solenoid valve.

Oil starvation/defective metering system.

Regulating valve stuck.

Pump Overheats. Pump oversized.

Miss-alignment of pump drive.

Dirt in oil.



12.8.5 Oil Flow Diagrams

ROTATION ROTATION

OIL RETURN

OIL UNDER PRESSURE

OIL UNDER SUCTION

PLUG OR VACUUM GAUGE PLUG OR VACUUM GAUGEPLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE

PRESSURE REGULATOR

OIL OUTLET TO NOZZLE

PLAN VIEW PLAN VIEW

PLUG OR SUCTION RETURN PLUG OR SUCTION RETURN

OIL INLET

½" B.S.P.P.

OIL INLET

½" B.S.P.P.

ALTERNATIVE OIL INLET ALTERNATIVE OIL INLET

OIL FLOW DIAGRAM FOR TYPE DH1 FUEL PUMPS

ROTATION ROTATION

OIL RETURN

OIL UNDER PRESSURE

OIL UNDER SUCTION


PRESSURE REGULATOR


RE

TU

RN

FR

OM

BU

RN

ER

SH

OW

N O

UT

OF

PO

SIT

ION

FO

R C

LA

RIT

Y

RE

TU

RN

FR

OM

BU

RN

ER

SH

OW

N O

UT

OF

PO

SIT

ION

FO

R C

LA

RIT

Y

OIL INLET OIL INLET OIL RETURNOIL RETURN

OIL FLOW DIAGRAM FOR TYPE DH1 (P) FUEL PUMPS

PLUGPLUG

PLAN VIEWPLAN VIEW



ROTATIONROTATION

OIL RETURN

OIL UNDER PRESSURE

OIL UNDER SUCTION

PLAN VIEWPLAN VIEW

PLUG OR VACUUM GAUGE PLUG OR PRESSURE GAUGE PLUG OR PRESSURE GAUGE PLUG OR VACUUM GAUGE

PRESSURE REGULATOR


PLUG OR

SUCTION RETURN

PLUG OR

SUCTION RETURN

OIL INLET

½" B.S.P.P.

OIL INLET

½" B.S.P.P.

ALTERNATIVE OIL INLET ALTERNATIVE OIL INLET

OIL FLOW DIAGRAM FOR TYPE DH2 FUEL PUMPS

ROTATIONROTATION

PLAN VIEWPLAN VIEW

OIL RETURN

OIL UNDER PRESSURE

OIL UNDER SUCTION


PRESSURE REGULATOR


RE

TU

RN

FR

OM

BU

RN

ER

SH

OW

N O

UT

OF

PO

SIT

ION

FO

R C

LA

RIT

Y

RE

TU

RN

FR

OM

BU

RN

ER

SH

OW

N O

UT

OF

PO

SIT

ION

FO

R C

LA

RIT

Y

OIL INLETOIL INLETOIL OUTLET OIL OUTLET

OIL FLOW DIAGRAM FOR TYPE DH2 (P) FUEL PUMPS

PLUGPLUG



NOTES

litres/Hr

2000

3000

1000

0

0 10 4020 30 bar

DHO-1

DH1-1

DHO-1

NOZZLE CAPACITY SINGLE STAGE PUMPS 2850 RPM

4kW

3

2

1

0

0 5 10 15 20 25 30 35 40 bar

DHO-1

DH1-1

DH1-2DH2-1

DH2-1

DH2-2

DH2-2

TYPICAL POWER CONSUMPTION 1425 RPM

kW 8

7

6

5

4

3

2

1

0

0 5 10 15 20 25 30 35 40 bar

DHO-1

DH1-1

DH1-2

DH2-1

DH2-1

DH2-2

DH2-2

TYPICAL POWER CONSUMPTION 2850 RPM

bar

2500

2000

1500

1000

500

0

0 40302010

litres/Hr

DHO-1

DH1-1

DH1-2

DH2-1

DH2-2

NOZZLE CAPACITY

SINGLE AND TWO STAGE PUMPS 1425 RPM

1000

bar

DH1-2

5000

litres/Hr

4000

3000

2000

0

0 10 20 30 40

DH2-2

NOZZLE CAPACITY TWO STAGE PUMPS 2850 RPM

LEGEND

10 cSt at 80ºC 3.5 cSt at 40ºC 1-2 cSt at 40ºC



DUNPHY COMBUSTION LTD

QUEENSWAY ROCHDALE ENGLAND OL11 2SL

Tel +44 (0) 1706 649217 Fax: +44 (0) 1706 655512 Internet – http://www.dunphy.co.uk

Documents

DUAL FUEL BURNERS · Operating Instructions For TD/TAD4 Dual Fuel Burner June 13 3 of 165 TD/TAD4 Manual Rev 4