SECTION 6 MAINTENANCE, PART NUMBER DIAGRAMS,

AND DRAWINGS

MAIN PARTS IDENTIFICATION - MR# DESCRIPTION DETAIL #

01 Feed Hopper 702 Feedroll Assembly 603 Combustion Fan Assembly 804 Gas Train Assembly05 Electrical Control Box08 Discharge Chute Assembly 509 Vibratory Tray 110 Screw Jack Assembly 212 Gas Frame/Manifold Assembly 419 Temperature Sampler 5

# DESCRIPTION DETAIL # 01 Feed Hopper 702 Feedroll Assembly 603 Combustion Fan Assembly 804 Gas Train Assembly 305 Electrical Control Box08 Discharge Chute Assembly 509 Vibratory Tray 110 Screw Jack Assembly 212 Gas Frame/Manifold Assembly 416 Heat Recovery Unit 717 90º bend Assembly 718 Extraction Fan 719 Temperature Sampler 5

AS S E M B L Y D E TAIL 7R E F . # D E S C R IP TIO N

G EN -0 1 -00 F EED H O P P ER A S S EM B L Y-01 H R U F u ll s e ns o r

G EN -1 6 -00 H EA T R EC O V ER Y U N IT-01 C a s c ad e-02 S q u a re / ro u n d t ra n s it ion-03 Te m pe ra tu re s e ns o r-04 G la nd - tem p . s en s o r-05 D o o r c a tc h-06 H R U /F e e d ro ll A da p te r-07 A la rm le ve l s e n s o r

G EN -1 7 -00 9 0 ° B EN D-01 C o n t ro l va lve a s s e m b ly

G EN -1 8 -00 EX T R A C T IO N F A N

ASSEMBLY DETAIL 1REF. # DESCRIPTION

MR -09 -00 TRAY ASSEMBLY - COMPLETE-01 Motor-02 Body-03 -00 Liner Set

-01 Liner - Back-02 Liner - Front

-04 -00 Mounting Set -01 Spring-02 Shock Absorber - Rubber-03 Safety Guard - Shock Absorber

GAS FRAME PARTS IDENTIFICATIONREF. # DESCRIPTION

1 INFRARED BURNER2 CURVED COPPER CONNECTING PIPE ASSEMBLY3 IGNITION TRANSFORMER AND HOUSING4 SPARK PLUG AND IONISATION PROBE ASSEMBLY5 CENTRELINE COPPER CONNECTING PIPE ASSEMBLY6 FLAME BAFFLE PLATES - PERFORATED7 FLAME BAFFLE PLATES - PLAIN8 IONISATION PROBE ASSEMBLY9 REFLECTOR PLATES

10 MANIFOLD11 TEST NIPPLE12 GAS PRESSURE BALANCE BOX

A S S E M B L Y D E T A I L 4 - 2R E F . # D E S C R IP T IO NM G E N - 1 2 0 - 0 0 G A S F R A M E / M A N I F O L D - C O M P L E T EM G E N - 1 2 1 - 0 0 G A S B U R N E R & P IP E W O R K - S E E D E T A IL # 4 - 1M G E N - 1 2 2 - 0 0 P L U G & P R O B E A S S E M B L Y

- 0 1 Io n i s a t i o n p r o b e- 0 2 Ig n i t i o n s p a r k p l u g- 0 3 E l e c t r o d e & m o u n t i n g p l a t e

M G E N - 1 2 3 - 0 0 I O N I S A T I O N P R O B E A S S E M B L Y- 0 1 Io n i s a t i o n p r o b e

M G E N - 1 2 4 - 0 0 Ig n i t i o n T r a n s fo r m e r ( S P E C IF Y V O L T A G E )- 0 1 H i g h t e m p e r a t u r e c a b l e ( Io n i s a t i o n p r o b e s )- 0 2 H i g h t e n s i o n c a b l e ( S p a r k p l u g s )

M G E N - 1 2 5 - 0 0 P E R F O R A T E D H E A T S H I E L D - 1 S E TM G E N - 1 2 6 - 0 0 S T A I N L E S S S T E E L R E F L E C T O R - 1 S E T

- 0 1 E n d ( ( s p a r k p l u g ) - m a c h i n e s p e c i f i c )- 0 2 E n d ( ( i o n i s a t i o n p r o b e ) - m a c h i n e s p e c i f i c )- 0 3 S i d e - 1 s e t ( m a c h i n e s p e c i f i c )

M G E N - 1 2 7 - 0 0 F L A M E B A F F L E P L A T E S E T ( E X T E R N A L )- 0 1 B a ff l e P l a t e - P e r fo r a t e d- 0 2 B a ff l e P l a t e - P l a i n

A S S E M B L Y D E T A I L 4 - 3R E F . # D E S C R IP T IO NM G E N - 1 2 0 - 0 0 G A S F R A M E / M A N I F O L D - C O M P L E T EM G E N - 1 2 1 - 0 0 G A S B U R N E R & P IP E W O R K - S E E D E T A IL 4 - 1M G E N - 1 2 2 - 0 0 P L U G & P R O B E A S S E M B L Y

- 0 1 Io n i s a t i o n p r o b e- 0 2 Ig n i t i o n s p a r k p l u g- 0 3 E l e c t r o d e & m o u n t i n g p l a t e

M G E N - 1 2 3 - 0 0 I O N I S A T I O N P R O B E A S S E M B L Y- 0 1 Io n i s a t i o n p r o b e

M G E N - 1 2 4 - 0 0 Ig n i t i o n T r a n s fo r m e r ( S P E C IF Y V O L T A G E )- 0 1 H i g h t e m p e r a t u r e c a b l e ( Io n i s a t i o n p r o b e s )- 0 2 H i g h t e n s i o n c a b l e ( S p a r k p l u g s )

M G E N - 1 2 5 - 0 0 P E R F O R A T E D H E A T S H I E L D - 1 S E TM G E N - 1 2 6 - 0 0 S T A I N L E S S S T E E L R E F L E C T O R - 1 S E T

- 0 1 E n d ( ( s p a r k p l u g ) - m a c h i n e s p e c i f i c )- 0 2 E n d ( ( i o n i s a t i o n p r o b e ) - m a c h i n e s p e c i f i c )- 0 3 S i d e - 1 s e t ( m a c h i n e s p e c i f i c )

M G E N - 1 2 7 - 0 0 F L A M E B A F F L E P L A T E S E T ( E X T E R N A L )- 0 1 B a f f l e P l a t e - P e r fo r a t e d- 0 2 B a f f l e P l a t e - P l a i n

ASSEMBLY DETAIL 4-1AREF. # DESCRIPTIONMGEN -12 -07 BURNER ASSEMBLY - COMPLETE

-08 Ceramic tile set - 4 off c/w fibre flax packing-09 Tile retainer set - 6 off-10 Gasket - venturi-11 Venturi - cast iron-12 Spreader plate-13 Fibre flax packing set (long & short)

ASSEMBLY DETAIL 4-1CREF. # DESCRIPTIONMGEN -12 -00 PIPEWORK ASSEMBLY - COMPLETE (STANDARD)

-02 Coupling assembly - upper-03 Copper pipe - curved (standard)

-06 Coupling assembly - lower (inc. 'A' joint & olive)

MGEN -12 -14 PIPEWORK ASSEMBLY - COMPLETE (CENTRE BURNER)-15 Copper pipe - centre burner

ASSEMBLY DETAIL 4-5 (2001 to DATE)REF. # DESCRIPTIONMGEN -122 -00 PLUG & PROBE ASSEMBLY

-01 Ionisation probe-02 Ignition spark plug-03 Electrode & mounting plate

MGEN -124 -01 High temperature cable (Ionisation probes)-02 High tension cable (Spark plugs)

ASSEMBLY DETAIL 4-5A (PRE 2001)REF. # DESCRIPTIONMGEN -122 -00 PLUG & PROBE ASSEMBLY

-01 Ionisation probe-02 Ignition spark plug

MGEN -124 -01 High temperature cable (Ionisation probes)-02 High tension cable (Spark plugs)

ASSEMBLY DETAIL 4 -6RE F. # D E S C RIP TIONM GEN -122 -00 P LUG & P RO BE AS S EM BLY

-01 Ionisation probe-02 Ignit ion spark plug-03 E lec trode & m ounting plate

M GEN -123 -00 IO NIS ATION P ROBE AS S EM BLYM G E N -124 -00 Ignit ion Trans form er (S P E CIFY V OLTA GE )

-01 High tem perature cable (Ionis ation probes )-02 High tens ion c able (S park plugs )

M GEN -128 -00 BURNER CO NTROLLER AS S EM BLY-01 B urner Control Unit (S P E CIFY V OLTA GE )-02 B ase - c ontrol unit

M GEN -129 -00 IG NITION S YS TEM CO M P LETE (P ER BURNER RO W )

ASSEMBLY DETAIL 8REF. # DESCRIPTIONMGEN -03 -00 COMBUSTION FAN ASSEMBLY

-01 Motor-02 Filter - inner-03 Filter - outer

ASSEMBLY DETAIL 2BREF. # DESCRIPTION

MR -02 -02 FLANGED COUPLING ASSEMBLY COMPLETE-01 Bell Housing-02 Toothed gear - male-03 Toothed gear - female-04 Spacer

MR -02 -10 TRANSDUCER CON ROD ASSEMBLY COMPLETE-01 Knuckle joint assembly-02 Shaft coupling

-11 MICRO-SWITCH CON ROD ASSEMBLY-01 Micro-switch-02 Connecting rod-03 Actuating lug

-12 TRANSDUCER-13 JAW COUPLING ASSEMBLY

-01 Jaw-02 Spider (rubber)

ASSEMBLY DETAIL 2AXREF. # DESCRIPTION

MR -02 -00 SCREW JACK ASSEMBLY (COMPLETE)-01 Motor - dual output shafts-02 Flange coupling assembly (complete) - see Detail 2BX-03 Bellows assembly (complete) - see Detail 2BX-04 Screwjack-05 Guard - Cardan shaft-06-07 Pin - screwjack top (std.)-08 Pin - screwjack bottom (std.)-09 Pin - screwjack top (transducer)-10 Transducer con. rod assembly (complete) - see Detail 2BX-11-12 Transducer-13-14 Cardan shaft assembly - see Detail 2BX-15 Screwjack rod end bearing

* For component and assembly details see draw ing DETAIL 2BX *

ASSEMBLY DETAIL 2BXREF. # DESCRIPTION

MR -02 -02 FLANGED COUPLING ASSEMBLY COMPLETE-01 Bell Housing-02 Elaflex coupling

MR -02 -03 BELLOWS ASSEMBLY COMPLETE-01 Folding bellows-02 Bellows mounting sleeve

MR -02 -04L SCREWJACK UNIT C/W SPINDLE & LH OUTPUTMR -02 -04R SCREWJACK UNIT C/W SPINDLE & RH OUTPUTMR -02 -06 SPRING 'R' CLIPMR -02 -07 PIN - SCREWJACK TOP (STD.)MR -02 -08 PIN - SCREWJACK BOTTOM (STD.)MR -02 -09 PIN - SCREWJACK TOP (TRANSDUCER)MR -02 -10 TRANSDUCER CON ROD ASSEMBLY COMPLETE

-01 Knuckle joint assembly-02 Shaft coupling

MR -02 -11 MICRO-SWITCH CON. ROD ASSEMBLY-01 Micro-switch-02 Shaft coupling-03 Actuating lug

MR -02 -12 TRANSDUCERMR -02 -14 CARDAN SHAFT AND COUPLING ASSEMBLYMR -02 -15 CARDAN SHAFT AND COUPLING ASSEMBLY

Function & Testing of Ionization Probes/Flame Rods

The function of the ionization probe is to sense the presence of flame and to tell the controller that each burner row has ignited or is alight. If no flame is present in a burner row after the ignition sequence at, initially, the first burner and then the last burner (after 15 seconds or more), the controller needs to take the appropriate actions, first of which is to close the main gas valves.

For reliable operation of the burner controllers it is important to understand the principles and limitations of ionization probe/flame rod based flame sensing to avoid ‘nuisance tripping’.

Principles of flame detection

Each burner controller applies alternating voltage between the probe and the base of the flame – the burner body (ground).

Current flow through the probe is essentially determined by the flow of electrons through it. However, the positive ions, which are concentrated close to the burner surface also play an important role in the flow of electrons. During combustion the hot burner metal surface gives up a few electrons from the surrounding atoms (just like a hot cathode in a valve) resulting in free electrons and positively charged atoms (‘ions’ - atoms which have lost an electron). The process is referred to as "ionization". The positive ions located near the burner immediately absorb such electrons to become inert atoms again. The electrons emitted by the burner surface are compensated by absorption of electrons by the probe, which are present at the periphery of the flame. It is this phenomenon that results in the flow of ionization current through the probe. Hence, for a good current flow to occur, the burner surface must be large and hot enough to generate sufficient electrons.

The ions in the flame provide a high resistance current path between the two. Because the surface of the base flame and the burner is larger than the sensing probe, more electrons flow in one direction than the other, resulting in a very small DC offset current (rectification). The DC offset is detected by the controller, which tells the gas valve to remain open. If there is no current flow, the controller will close the gas valves. On re-start the system will purge itself of any remnant gas before trying to re-ignite.

Limitations

Product build-up, dirt, corrosion, or bad connections in the flame sensing circuit will oppose or resist the flow of the rectified current and cause the controller to think the burners are not alight. Monitoring the flame current on a regular basis will show the flame signal degrade as oxidation and contaminants build up.

A good clean flame rod and grounding surface at both the burner and burner controller is imperative to allow the control to recognize this rectification occurring. During maintenance it may be necessary to sand both, the burner tile retainers and fixings, as well as the flame rod to ensure they are always clean.

TXT-GEN-DET-4.8A

The current in the ionization probe is normally measured by a meter in series with the rod. The meter is capable of measuring between 1 - 50 microAmps DC and in some cases currents in excess of 15 - 20 microAmps are possible.

For ignition systems where a micro ammeter is not supplied, any meter with micro amps can be connected in series between the controller and the flame-sensing rod. When the flame is on, there should be a measurable microAmp DC signal, typically around 10 - 12 µA. If the signal is < 6 µA, the controller will perceive this as a "no-flame situation" and the gas valves will close.

What to check:

1) If the current is too low, check to make sure the connections from the controller to the ionization probe and the connection from the controller ground to the probe ground is low (it should be < 100 ohms). 2) If current is fluctuating, increasing or decreasing with time when the heater is running, check if the sensing rod, as it heats up, is bending towards or away from the burner surface. Excessive bending can cause the rod to short to ground when it comes into close proximity with the burner retainers.

3) With burners OFF, check the AC voltage between the ionization probe and the base of the flame (burner tile retainer nearest to the probe) with control power ON.

First measure the AC voltage from the ionization probe’s sensing rod to ground and then to the tile retainer (that forms the base of the flame). If there is no voltage, check the voltage to the probe connection, check the condition of the wire from the controller to the ionization probe and whether securely connected, or if the probe or the wire has become grounded. Check the above, also, at the terminals within the Micronizer control panel.

If there is still no voltage turn control power OFF and check the integrity of the ionization probe e.g. no short circuit between sensing rod and surround. 4) If voltage is present, make sure the sensing rod and the local burner retainer are clean and free of dust, dirt or debris. If they are not, turn the power off, take them out clean them and reinstall. Cleaning the probe sensing rod and burner retainer will remove impedance from the flame current circuit and thus should increase flame current.

TXT-GEN-DET-4.8B

BURNER CONTROL TIMING SEQUENCE - LANDIS and STAEFA (LFL 1.635)

``

IGNITION (Z) - TERMINAL 16

PILOT VALVE (ZBV) - TERMINAL 17

MAIN VALVE (BV1) - TERMINAL 18

IGNITION TRANSFORMER - ON

BY-PASS FUEL VALVE (PVR) - OPEN

MAIN FUEL VALVE (MVR) - OPEN

COMBUSTION FAN - ON

CHECK AIR PRESSURE > LOW LIMIT

CHECK FLAME SIGNAL AT FIRST BURNER

CHECK FLAME SIGNAL AT LAST BURNER

CHECK GAS PRESSURE < HIGH PRESSURE AND > LOW PRESSURE

TIME (IN SECONDS)5.0 75.0 77.5 80.0 82.5 97.5 105.0

A B72.5

CHECK AIR PRESSURE ZERO

10.00

A4 - BCTS-LS/1

S P A R K A R R E S T O R - P A R T S I D E N T I F I C A T I O NR E F . # D E S C R IP T IO NS P K A - 0 1 - 0 0 D R I V E A S S E M B L Y

- 0 1 M o t o r- 0 2 G e a r b o x

S P K A - 0 2 - 0 0 S C R A P E R A S S E M B L Y- 0 1 S c r a p e r b a r - a n g l e d a s s e m b l y- 0 2 S c r a p e r b a r - h o r i z o n t a l a s s e m b l y

S P K A - 0 3 - 0 0 T E M P E R A T U R E S A M P L E RS E E A S S E M B L Y D E T A I L 5

S P K A - 0 4 - 0 0 C O N T R O L P A N E L A S S E M B L Y- 0 1 T e m p e r a t u r e d i s p l a y / t r a n s m i t t e r- 0 2 S p e e d C o n t r o l l e r - T e m p e r a t u r e S a m p l e r - 0 3 S p e e d C o n t r o l l e r - D i s c h a r g e c o n v e y o r ( S t a t e v o l t a g e )

S P K A - 0 5 - 0 0 L E V E L S E N S O RS P K A - 0 6 - 0 0 L O A D C E L L A S S E M B L Y ( W H E R E F I T T E D )

- 0 1 L o a d c e l l - a c t i v e- 0 2 L o a d c e l l - d u m m y- 0 3 L o a d c e l l - d i s p l a y / t r a n s m i t t e r

S P K A - 0 7 - 0 0 H O P P E R A S S E M B L Y- 0 1 H o p p e r b o d y ( i n c . s t u b l e g s )- 0 2 S u p p o r t l e g f r a m e

COOLER - PARTS IDENTIFICATIONREF. # DESCRIPTIONC1010 -01 -00 MAIN DRIVE ASSEMBLY

-01 Motor-02 Sprocket assembly-03 Key - taperlock to shaft-04 Chain

C1010 -02 -00 SECONDARY DRIVE ASSEMBLY-01 Sprocket assembly-02 Drive Shaft-03 Key - Taper lock to shaft-05 Bearing assembly - complete-08 Grease nipple

C1010 -03 -00 CONV. CHAIN & SPROCKET AS'BLY-01 Sprocket - 8 tooth-02 Chain Complete-03 Joining link - plain-04 Joining link with F1 attachment (when fitted)-05 Flight - Angle-06 Flight - Flat (when fitted)-07 Keyway - 8 tooth sprocket to shaft

C1010 -04 -00 LOUVREC1010 -05 -00 IDLER ASSEMBLY

-01 Bearing assembly - complete-04 Grease nipple-05 Shaft - idler

COOLER - PARTS IDENTIFICATIONREF. # DESCRIPTIONC1010 -01 -00 MAIN DRIVE ASSEMBLY

-01 Motor-02 Sprocket assembly-03 Key - taperlock to shaft-04 Chain

C1010 -02 -00 SECONDARY DRIVE ASSEMBLY-01 Sprocket assembly-02 Drive Shaft-03 Key - Taper lock to shaft-05 Bearing assembly - complete-08 Grease nipple

C1010 -03 -00 CONV. CHAIN & SPROCKET AS'BLY-01 Sprocket - 8 tooth-02 Chain Complete-03 Joining link - plain-04 Joining link with F1 attachment (when fitted)-05 Flight - Angle-06 Flight - Flat (when fitted)-07 Keyway - 8 tooth sprocket to shaft

C1010 -04 -00 LOUVREC1010 -05 -00 IDLER ASSEMBLY

-01 Bearing assembly - complete-04 Grease nipple-05 Shaft - idler