Oil Burner Manual

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DESCRIPTION OF PA INDUSTRIAL OIL BURNER

(A) BURNER:

PA INDUSTRIAL OIL BURNERS are pressure jet and spill return typeburner with the turn down ratio of 1:3 and 1:4 i.e. 1/3rd or 1/4 th of the oilcapacity is atomized at low flame position and remaining 2/3rd or 3/4thcapacity is modulated by burner modulating drive between high flame to lowflame positions. The principle of modulation is by regulating the return oilpressure after the nozzle. The return oil pressure is regulated by return oilpressure regulating valve or (Back pressure regulating valve) BPRV whichis actuated by a cam disc arrangement driven by a modulating servo motorthrough the gear drive mechanism. The air damper is mechanically coupledwith the drive unit to keep the air fuel ratio constant throughout themodulating range.A photoresistor is mounted on the burner front as a part of the combustionsafety control. The photoresistor, when exposed to the flame provides electricalcontinuity to the burner program cycle in the sequence controller. In case offlame failure condition, photoresistor shuts off the burner firing system.A rated capacity of the nozzle is fitted on the burner rod assembly ornozzle rod. Burner rod is actuated by a DC operated solenoid assembly. Theoil is atomized and ignited by means of a high voltage ignition sparkestablished at the ignition electrodes end near the nozzle. The ignition voltageof 14.5kv is provided by an Ignition Transformer mounted on the burner.

(B) COMBUSTION AIR:

The fuel oil combustion is supplied with sufficient combustion air by a forceddraught fan mounted below the burner. The required quantity of air atrequired delivery head is provided for operating the boiler/Furnace/Heatgenerator under forced draught condition. Forced draught fans are normallycoupled directly with motors. The burner and the force draught fan are coupledby means of a leather bellow to prevent the transfer of vibration to theburner. The PA burners are suitable to operate on ambient air temperature.Special burners are available for High combustion air Temp. applications.

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(C) GEAR OIL PUMP:

The pressure jet Oil burner requires higher fuel oil pressure to obtain the betteratomization & higher combustion efficiency. The high pressure positivedisplacement type Gear oil pumps are specially designed for handling viscousfuel oils (Heavy Oil) like furnace oil etc. It is capable of developing veryhigh pressure up to 25 kg/cm2. A control valve with built in by-pass isprovided in the pump for controlling delivery oil pressure. A set screw isprovided for setting the required oil pressure.

(D) INLET PRESSURE REGULATING VALVE: (FIG 1A)

The burner inlet oil pressure can be adjusted and maintained by this valve.Normally inlet oil pressure for the burner is maintained within 20 kg/cm2 to25 kg/cm2 range for proper atomization of the fuel oil. This is a springloaded control valve with built in by-pass arrangement. Inside the pressurecontrol valve, a piston (1), moving in a valve body, is forced against thevalve needle (3) by a spring (2). If the pressure on the valve needle side isgreater than the pressure exerted by the spring, the piston will rise and theoil will flow over the un-pressurised side. Hand wheel (4) is provided to setthe required oil pressure. The following instructions are important for installingthis IPRV valve. The spring side is always the return side i.e. the un-pressurised side. The direction of overflow is from the pressure side to thespring side. For functioning of the valves, it is immaterial whether they areinstalled in continuos lines or at the end of lines, clockwise rotation of thehand wheel corresponds to an increase in the oil pressure, and Anti-clockwise rotation to decrease the oil pressure.

IPR Valve size 3/4” - Max. Flow 2000 LPHIPR Valve size 3/8” - Max. Flow 800 LPH

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-3-(E) RETURN OIL PRESSURE REGULATING VALVE: (FIG-2B) OR BACK PRESSURE REGULATING VALVE (BPRV)

As mentioned earlier, quantity of the oil atomized by the nozzle depends uponthe return pressure or the back pressure of the Fuel oil, hence Fuel oiloutput of the burner is regulated by changing the return oil pressure. A camdisc is provided with this valve to vary the back pressure. The cam disc isdriven by a modulating drive assembly.

ADJUSTMENT PROCEDURE OF BPR VALVE AND CAM DISC:

Adjust back pressure regulating valve on the compound control with camdisc. Switch on the burner Fuel oil pump in manual mode, check the oilcirculation and read the back pressure on the return oil pressure gauge.Remove cover from the modulating drive unit, depress the clutch (16), androtate manually up to max high flame position. In order to prevent the returnof the drive unit to normal, disconnect proper wire from the control circuit.The maximum pressure on the return line can again be read on the pressuregauge.- To attain the control ratio of 33% -100% , the return oil pressure should

be approx. 2 -18 kg/cm2.- If the pressure have to be altered. slacken the hex. socket head screws on cam disc (8) , by rotating the set screw (9) of cam disc clockwise, the lifting difference will be reduce, i.e. the difference between the min and max pressure will be less.- By rotating the set screw in an anti-clockwise direction, the lifting difference will increase, i.e. the difference between min and max pressure will be greater.- By slackening the lock nut (4), and rotating the spindle, the tension of spring (3) in the return control valve can be altered.- A steadily increasing pressure between min and max can be achieved by means of the tension of spring (3) and the eccentric cam disc (2).- After completing the adjustment, tighten the hex. socket head screw (8) and lock nut (4).- Take the trial run by taking the drive unit to high flame and low flame positions, to obtain the required return oil pressure.- Depending upon the nozzle capacity & size, return oil pressure variation may be observed on firing the burner.

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(F) MODULATING DRIVE UNIT TYPE PA / AR-63: (FIG-4A)

The drive unit PA / AR-63 consist of 1 no. reversible AC servomotor (1) withbrake assembly, driving the set of reduction gears (2) and cam disc spindle(3). Air regulating drum (4) is mounted on the cam disc spindle. The spindlerotation from low flame to high flame position is limited to 180 deg by 4nos. cam operated micro switches.

Burner air damper is mechanically coupled to the air regulating drum bysteel band arrangement. By this arrangement Precise regulation of the airquantity is possible for all firing positions, between low flame to high flamefor obtaining optimum combustion efficiency.

FOR STEAM BOILER APPLICATION:

Proportionate burner modulation control is achieved with the modulating driveunit PA / AR-63. The above system will operate in conjunction withpositioner controller type PEPC-10, pressure transmitter with potentiometer(mounted on the boiler) and feed back potentiometer mounted in the burnermodulation drive unit. (As an optional accessories). Depending upon the steampressure variation, burner modulation will be adjusted automatically, tomaintain the constant steam pressure at all the variable loads. For details referthe attached literature.

(OPTIONAL ACCESSORIES)

1: Positioner controller type PEPC-10. (Panchal Associates make)

2: Pressure transmitter with 135 ohms potentiometer. (Honeywell L91B)

3: Feed back potentiometer 135 ohms or 150 ohms. (Burner modulation Unit)

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FOR FURNACE, HOT AIR GENERATOR APPLICATION:

Proportionate burner modulation control is achieved with the modulating driveunit PA / AR-63. The above system will operate in conjunction with the PIDcontroller with potential free Heat/Cool relay output, Rtd, Pt-100 input,Temperature sensor (mounted on the Furnace) and feed back potentiometermounted in the burner modulation drive unit. (As an optional accessories).Depending upon the temperature variation, burner modulation will be adjustedautomatically, to maintain the constant temperature at all the variable Heatloads. For details refer the manufacturer literature.

MODULATING DRIVE UNIT TYPE PA / AR-63: (FIG-4A)

The two media oil and air can be adjusted independently as regards of theirquantity and ratio, by means of PA / AR-63 modulating drive unit.

1- Reversible servomotor with brake2- Reduction gear train drive3- Cam disc spindle4- Air regulating drum5- micro switch cam6- micro switch no 3 for low flame motor supply7- micro switch no 4 for min limit position (low flame position check)8- micro switch no 2 for High flame motor supply9- micro switch no 1 for low flame motor supply

Refer Burner wiring diagram for micro switches connection

NOTE: Improper micro switches connection may over-run the gear drive unitand may get damaged .Check the gear drive unit for low and high flamelimit positions.

MODULATING DRIVE UNIT PA / AR-63TECHNICAL DATA

Reversible servomotor motor with built in brake assemblyAC input voltage : 230v , 50 HzPower input : 2 X 110 wattLoad on end shaft : 3 kg-m cont-6-

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Running time : min-max aprrox. 27 secNormal Rotation : 180 deg for adjustment.Complete shut-off of air : additional running time withDampers additional rotation of 90 deg

AIR ADJUSTMENT PROCEDURE ON DRIVE UNIT PA / AR-63

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- Set the required quantity of air on the regulating drum (1) by means of 6 mm. hex. wrench.

- 16 adjustable cams (2), holding the flat spring steel band, are fitted to the regulating drum. 5 nos. cams are for the air shut-off, the remaining 11 nos. cams are for regulating the air damper.

- The adjusted curve of the spring steel band (4) is transmitted to the air dampers by means of a pick-up arm (3).

- The air quantity is adjusted by rotating screw (5) . clockwise rotation of screw (5) will reduce the air quantity and anti-clockwise rotation will increase the air quantity.

- The drive is manually rotated, from one adjusting cam to the next

- starting at the minimum oil operation position and the air is allocated to the corresponding screw 5.

- At least Three cams must be successively adjusted each time. The position distance between the cams should not exceed 4 mm otherwise spring steel band might break.

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(G) NOZZLE ROD OR BURNER ROD:

Nozzle rod distributes the oil flow to the nozzle and balance to the returnline. Rated capacity nozzle is fitted to the nozzle rod. Different length ofnozzle rods are selected for different types of burners. (Length between twoblocks of nozzle rod)

SPECIFICATIONS:

Temperature of medium - max. 150 Deg COperating pressure - max. 30 barOil throughput - 30 - 1000 kg/hrSwitching frequency - max. 20/min.Nozzle fixing thread - M 14 x 1.5

OPERATION:

Oil at a regulated pressure, from IPR valve and strainer filter is supplied tothe nozzle rod inlet port (6). and return from the nozzle is to the returnport (7). When the nozzle rod is in a closed position by-pass passage in thefront block is open and the oil circulates through the by-pass. Spring loadedneedle valves 3&4 are in a closed position. At the time of firing, the DCoperated nozzle solenoid (11) gets energized and opens the needle valves at thesame time, piston (5) block the bye-pass passage and the oil will flow through theneedle, seat and to the nozzle for atomization. Balance oil will return throughneedle valve (4) and to the return port.

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BURNER ROD PART DESCRIPTION (FIG-9A)

NO PART

1 - Cap nut M6 2 - Lock nut M6 3 - Needle valve rod (Inlet) 4 - Needle valve rod (return) 5 - needle rod pistons 6 - Inlet oil port 7 - Return oil port 8 - Bracket 9 - Sealing plugs 10 - Springs 11 - Needle rod seats 12 - Seats sealing copper washers 13 - Front sealing plugs 14 - Plugs sealing washers 15 - By-pass cleaning screw 16 - Spring retainer 17 - ' U ' oil seal 18 - ' U ' oil seal holder 19 - seal holder plug 20 - Transmission lever 21 - Mating plate 22 - Spring tension adjuster 23 - Fork connection pin 24 - Allen screw for rod mounting

L = 460 mm for burner type PA 15 L = 610 mm for burner type PA 20 L = 710 mm for burner type PA 25 L = 960 mm for burner type PA 35 L = mm for burner type PA 45 L = mm for burner type PA 50

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ADJUSTING THE TRANSMISSION LEVER (FIG-10A)

To adjust the transmission lever (5), the nozzle solenoid (1) must bede-energized.

(1) Pull out plunger (2) as far as it will go.

(2) The distance between the transmission lever (5) and its mating plate should not exceed 1.00 mm.

(3) ADJUSTING THE CORRECT SETTING:

- Slacken lock nut (3) and rotate plunger (2) until the correct setting is obtained.- Check the needle valve opening for approx. 4.00 mm to 5.00 mm. When nozzle DC solenoid is energized.- Tighten lock nut (3).

IMPORTANT:

- Both the needle valves (6) must be actuated simultaneously.- If a correction is required, slacken the cap nut (9) , reset with the aid of the nut (10) and re-tighten the cap nut.

DISMANTLING THE NOZZLE ROD:

1. Close all the isolating valves on the burner Fuel oil lines.

2. Remove the pin (23) connecting the transmission lever to the DC solenoid assembly fork.

3. Remove screw (24) holding the nozzle rod and oil distributor together.

4. Slightly lift and withdraw the nozzle rod.

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IMPORTANT:

Before removing the screw (24), depress the transmission lever to releasethe oil pressure inside the nozzle rod.

(H) NOZZLE: (TYPE PA/DZ)

The nozzle type PA/DZ is fitted to the PA make pressure jet oil burners.Nozzle capacity depends upon the max. Oil firing capacity selected for theburner.

Inlet oil pressure in the range of about 20 kg/cm2 to 28 kg/cm2 issupplied to the nozzle through the nozzle rod. Fuel oil at the higher pressureenter the swirl chamber of the Nozzle and gets mechanically atomized in theform of a fine oil spray . This spray is ignited by ignition spark to establishthe oil flame. Spray angle depends upon the type of nozzle selected. As theinlet oil pressure increases the quality of atomization gets improved andbetter fuel combustion is achieved.

Depending upon the return oil pressure, oil firing rate will vary frompartial load to full load. At the max. Recommended return oil pressure, max.oil firing capacity can be obtained. The spray angle varies between highflame to low flame positions. The angle increases as the capacity decreases.

If the return pressure or the supply pressure is too high, there will beexcess pressure at the nozzle tip i.e. the oil will be discharged in the formof a straight jet and will no longer be atomized . In this case, the return oilpressure must be reduced.

Excess oil after the atomization from the nozzle, return through the centerbore of the swirl chamber and flow to the return pressure regulating valve.

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RETURN PRESSURE VS CAPACITY DIAGRAM FOR NOZZLE PA - DZ:

Spill Return type nozzle PA-DZWith regulated return flow

Fuel oil: Light oil/Heavy oilInlet oil pressure : 24 kg/cm2Connection : Thread M 14 x 1.5

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SPILL RETURN TYPE NOZZLE PA -DZ

1 - Nozzle Body2 - Swirl chamber OR Atomizer3 - Nozzle Tip with brass washer

SPECIFICATION:

Inlet oil pressure - 20 kg/cm2 to 28 kg/cm2Return oil Pressure - 3 kg/cm2 to 18 kg/cm2Viscosity range - 1.8 to 2.2 deg EnglerCapacity - 50 kg/hr to 1000 kg/hrSpray angle - 45/55 deg for standard versionControl range - 1 : 3 turn down ratio for standard version 1 : 4 turn down ratio (Optional)Application - Suitable for mounting with PA NOZZLE RODS / BURNER RODSRemarks - Do not interchange the swirl chamber and the nozzle tip , since they are mutually matched

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DISMANTLING:

- Hold the nozzle body (1) in the vice clamp.- Dismantle threaded sleeve (6) with a spanner.- Slacken, and dismantle swirl chamber (2) with 6 mm Allen key.- Push back the nozzle tip (3).

ASSEMBLY:

- Place the brass or copper washer (4) on the nozzle tip (3) in the correct position and insert in the nozzle body (1) up to the front end .- Screw in and tighten swirl chamber (2) by a 6 mm Allen key- Place Brass or copper washer (5) on the threaded sleeve (6) and tighten with spanner.

CLEANING:

- Clean all the dismantle parts with clean kerosene or petrol by a soft brush.- DO NOT use metallic brush, cotton waste , emery paper, wool or any similar type of material for nozzle cleaning.- DO NOT clean nozzle tip bore with any type of metallic needle, wire etc.- Clean and dry all the parts with compressed air and assemble as stated earlier.

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-16-NOZZLE PROBLEMS:

Leakage:

(A) - If nozzle washers (4) , (5) & (7) are not tighten fully, leakage of Fueloil from this washers may give smoky combustion or oil may splash on thediffuser plate and furnace walls, forming carbon clinkers.

Imperfect atomization:

(A) - If inlet and outlet of nozzle is interchanged there will not be proper atomization but the spray will be in the form of a jet.(B) - Swirl chamber (2) is NOT FULLY tighten against the nozzle tip (3) by 6 mm Allen key.(C) - The swirl chamber sealing face is damaged.(D) - Nozzle tip bore or swirl chamber slots may get clogged with foreign particles.(E) - Supply oil inlet pressure and temperature may be too low.

Precaution:

Nozzle is a critical component for the burner as far as combustion isconcerned. DO NOT interchange tip or swirl chamber from differentnozzles since they are mutually matched & tested.

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SOLENOID ASSEMBLY (CONTINUES CURRENT MAGNET) (FIG-16A)

PART DESCRIPTION

(1) MS Body(2) MS removable front cover(3) MS rear cover(4) Brass front plunger guide bush(5) Brass rear plunger guide bush(6) MS Plunger with SS shaft(7) Solenoid DC Coil(8) Brass washer(9) Coupling fork(10) Lock nut

SPECIFICATION:

- Pulling force - 14 kg- Stroke length - 23 mm- DC Voltage - 180-230 VDC- DC Current - 0.35 to 0.45 Amp- Plunger thread - M12- DC Coil resistance - 500 Ohms approx.

IMPORTANT:

1) Prevent dust, Oil , entering the solenoid assembly. Provide rubber dustcover.

2) Check for free movement of the Plunger.3) Lubricate the plunger shaft with lub. Oil, as & when require.4) Check DC supply voltage for any pulling problem, Min. DC voltage

require 180 VDC. Use Bridge rectifier of proper voltage & currentcapacity.

5) If the Dc voltage is proper & still pulling problem persist, check the springtension of the Burner rod.

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DESCRIPTION OF OIL FLOW SCHEMATIC (P & I DIAGRAM) (FIG-18A)

1 - The fuel oil from the main storage day tank is supplied to the circulatingheader through ' y ' type strainer oil filter. The oil holding capacity of thecirculating header depends upon the type of burner selected.

2 - The oil outlet from the circulating header is connected to the inlet ofDuplex type Fuel oil filter. The filtered oil is supplied to the suction port of thepositive displacement type Gear oil Pump of rated capacity.

3 - The oil pump discharge end is connected to the Inlet Oil Pressure RegulatingValve (IPRV) where burner oil Inlet pressure is regulated and remaining excessoil is returned back to the circulating header through IPR Valve internal bye-pass.

4 - The fuel oil at a regulated pressure is supplied to the series of oilpreheaters such as steam pre-heater , electric pre-heater etc. for preheating theheavy fuel oil. Temperature of the oil is regulated by oil thermostatsprovided on the oil preheaters. Light fuels like LDO (Light Diesel Oil ) donot require any type of preheating for firing.

5 - Preheated oil a regulated temperature and pressure is supplied to themicro filter and finally to the nozzle rod inlet port in the burner. Oilcirculates through the nozzle rod by-pass & returned to the back pressureregulating valve (BPRV). From BPRV outlet, oil is returned to the circulatingheader. Oil circulation continues till the required oil temperature is achieved.

6 - Before installing the new oil pipe lines be ensure that the rating & size ofthe oil lines are suitable for burner inlet and return pressure.

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OIL FLOW DIAGRAM PARTS DESCRIPTION (FIG-18A)

NO PART

1 Service oil tank with oil preheater (Day tank)2 Isolation valve3 Oil strainer4 Isolation valve for circulating header oil inlet5 Isolation valve for circulating header vent line6 Oil circulating header7 Isolation valve for circulating header burner return8 Isolation valve for circulating header burner oil inlet9 Drain valve10 Duplex oil filter11 Isolation valve to oil pump suction line12 Isolation valve to oil pump discharge line13 Inlet oil pressure regulating valve (IPRV)14 Steam preheater15 Isolation valve for steam preheater16 Electric oil preheater17 Isolation valve to burner inlet oil line18 Micro oil strainer with thermometer19 Burner inlet oil pressure gauge with needle valve20 Burner rod assembly (Nozzle rod)21 Burner return oil pressure gauge with needle valve22 Back pressure regulating valve (BPRV)23 Isolation valve burner return line24 Cam disc assembly25 Oil pump26 Oil Burner

Burner type PA 15 - Circulating header capacity 40 liter PA 20 - Circulating header capacity 50 liter PA 25 - Circulating header capacity 50 liter

Burner type PA 35 - Circulating header capacity 100 liter PA 45 - Circulating header capacity 100 liter PA 50 - Circulating header capacity 100 liter

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BURNER COMMISSIONING

Check prior to igniting the burner:

- Flush out all the oil pipelines by compressed air or water by tapping it at regular intervals to remove residual welding flux, foreign Particles etc.

- Tighten all the joints and check the gaskets provided in the oil Circulating system.

- Open and check all the strainer for proper filter elements.

- Open all the air vents in the oil lines and oil isolating valves as require .

- Check all the safety interlocks provided on the equipment for their normal functioning.

- Ensure that the electrical wiring and connections are in order

- Check the direction of rotation of the combustion Air blower, Fuel Oil pumps & other equipment installed.

- Adjust the thermostats settings on the oil preheaters.

- Keep the IPR valve settings at min. positions for initial start up.

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Igniting the burner (Manual mode)

- Switch on the blower, Fuel oil pump and oil preheaters.

- Adjust the Fuel oil pump discharge pressure by built in relief valve and burner inlet oil pressure by IPR valve between 20 - 28 kg/cm2 by hand wheel provided on IPRV.

- Adjust the return oil pressure from BPR Valve top side, between 3 – 6 kg/cm2 by Allen wrench.

- Check burner damper in min. position (low flame) and fuel oil temperature before igniting the burner.

- Switch on the ignition spark at the nozzle tip.

- Check Ignition spark from the burner view glass for normal bright Spark.

- Operate the nozzle DC solenoid to release the fuel oil from the nozzle.

- Check the flame from the burner view glass, once the burner is ignited.

- If the flame is found normal, adjust the air fuel ratio by adjusting the return oil pressure and combustion air for low flame and high flame positions as described earlier for obtaining max. output and efficiency.

CAUTION: WHEN BURNER IS FIRED IN MANUAL MODE, OPERATORSCONTINUOUS ATTENTION IS REQUIRE AS FLAME FAILURE SAFETYFEATURE MAY NOT BE AVAILABLE IN THE MANUAL FIRING M ODE.

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Ignition of the burner in (Auto mode )

- Switch on the burner control switch in auto mode.

- The blower , oil pump and oil preheaters are switched on automatically.

- If the combustion air pressure (If Air Pr. switch is provided) and Fuel oil temperature are normal and the burner is in min. position. The burner sequence controller is switch on for auto operation.

- Burner goes to pre-purge cycle (If provided) by opening the air damper at max. open damper position . (High flame )

- On expiry of pre-gauge cycle burner returns back to min. damper position (low flame )

- On preset delay of the controller, the High Voltage ignition spark is established at the nozzle tip.

- Nozzle DC solenoid operates to release the fuel oil from the nozzle.

- The flame is established and sensed by the photoresistor for further Burner sequence.

- Burner goes to modulating mode and max. damper opening position (High flame ) depending upon the load demand of the equipment.

- If the flame is not established during safety period of the controller, burner goes to lockout automatically, giving audio visual alarm.

NOTE: Burner auto sequence may vary depending upon the type of sequence controller is used .

It is advisable to operate the burner in AUTO mode only, to ensure theoptimum safety of the burner, operating personnel and the equipment.

IT IS ALWAYS ADVISABLE TO FIRE THE BURNER IN AUTO MODE ONLY.

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COMMON BURNER FAULTS AND THEIR REMEDY:

(1) Burner does not start:

FAULT REMEDY

(A) Power supply to the equipment Check power supply. is disconnected.

(B) The safety interlocks of the Check the interlocks equipment is interrupted.

(C) Air pressure switch for combustion Check the Air Pr. switch. air is not switched on. (If provided)

(D) Sequence controller is defective Replace it.

(E) Motor protection overload relays Check it. for blower or oil pump is tripped.

(F) Limit switch in the flue gas damper Check it. is not operated. (If provided)

(G) Min. oil temp. thermostat is defective Check it. or the oil temp. is too low.

(H) After pre-purging, min. damper micro Check it. switch for starting position is not pressed or may be defective.

(I) Flame sensor receives stray light from Check photoresistor the external sources. Check nozzle rod for leakage, or there may be oil accumulation in the furnace.

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(2) Burner does not ignite:

FAULT REMEDY

(A) No ignition spark, there may not Check Ignition Transformer be voltage at ignition transformer

(B) Ignition electrodes point gap too Adjust the point gap for big or too small 6 to 8 mm.

(C) Porcelain insulator of the electrode Check and replace it. is cracked or dirty.

(D) Ignition electrodes tips are dirty. Clean it.

(E) Too much combustion air at starting Reduce the Air from air position. drum in the modulating unit by 6 mm Allen key.

(F) Sequence controller is defective. Replace it .

(G) The DC solenoid is defective. Check the rectifier and solenoid coil. Check DC voltage around 180-230v

(H) Nozzle is clogged or defective. Check and clean, or replace it.

(I) Oil temp is too low, quality of Check oil temp. atomization is inadequate for Check oil preheaters. firing. Check oil thermostats.

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(3) Burner ignites but immediately switches off:

FAULT REMEDY

(A) Flame sensor receives insufficient Photoresistor sensor side light . is not facing towards the flame Check for any type of obstruction in front of the photoresistor OR flame sensor.

(B) Flame sensor is dirty or defective Clean it or replace it.

(C) Sequence controller is defective Replace it .

(D) Flame is unstable due to excessive Adjust the air on air drum combustion air supply .

(E) Variation in inlet oil pressure and Check the burner oil return oil pressure . pressure.

(4) Burner smokes heavily:

FAULT REMEDY

(A) Too much oil output from Check return oil pressure. The nozzle. If require adjust the BPRV and cam disc

(B) BPR valve is faulty. Replace it.

(C) Burner return line isolation In this case burner inlet valve may be closed. oil pressure and return oil pressure will be equal, find out the blockage.

(D) Cam disc eccentricity is too high, Adjust the cam disc return oil pressure increases Reduce the return oil pressure

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(E) Air damper opening is too low Increase the air by adjusting the air damper .

(F) Heavy leakage from the nozzle and Check the sealing washers Nozzle rod sealing washers at the for nozzle and tighten it time of firing . fully by proper spanner.

(5) Problems related to the air regulating unit PA – AR63

FAULT REMEDY

(A) Air regulating unit is not reaching Check the micro switches to the min. and max. limit positions for min. and max. limit and overshoots. positions. Check the connections of the reversible servomotor.

(B) Air regulating drum is jammed and Check the Allen bolts can not be rotated by hand when provided for clamping the de-clutching gear is pressed . BPRV bracket and unit. If longer bolts are used it may press the gears, change the bolts. Check burner air damper for jamming, lubricate the Bearings. Check the gear train and if require lubricate it. Modulating drive unit is faulty.

IMPORTANT:

Jammed air regulating unit may overload the gear drive and servomotor mayburn out.

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MAINTENANCE BY THE OPERATING STAFF

(A) Daily inspection

- Check flame through the burner sight glass to ascertain the formation of the soot or clinker in the combustion chamber.

- Check the diffuser plate and flame tube for cleanliness by viewing through the sight glass.

- Check the burner oil pressure and temperature.

- Observe the ignition spark and nozzle DC solenoid movement .

- Check the burner tripping by pulling out and masking the flame sensor.

(B) Weekly inspection

- Clean and check all the oil filters.- Attend all the oil leakage from the oil lines.

- Monthly inspection

- Clean the diffuser plate and the flame tube if the clinker or sootformation is observed on it.

- Clean the ignition electrodes tip by solvent to remove the carbon particles.

- Clean and lubricate the AR63 modulating unit gear drive assembly .

- Check the burner electrical connections.

- Clean and lubricate the nozzle DC solenoid plunger by lubricating oil.

- Clean and check the porcelain insulators of the ignition electrodes

- Clean and check the nozzle.Cont -28-

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(D) Quarterly inspection

- Check and lubricate the air dampers Bearings.

- Lubricate the AR63 servomotor motor bushings/Bearings by lubricating oil.

- Check BPRV cam disc for any wear and tear.

- Check the ' U ' seals of BPRV, Nozzle rod, IPRV etc.

FLAME TUBE ARRANGEMENT: (FIG-29A)

Flame tube is a cylindrical shell with two slotted holes on both the sides.These are required for forward and backward adjustment of flame tube withrespect to diffuser and nozzle. After the adjustment, the adjustment bolts (2)are tightened fully. Two nos. fixing bolts (1) are provided (one at the topand other at the bottom) for preventing the flame tube from sagging duringoperation.The distance between the diffuser plate and flame tube as shown X in thediagram, has been specified for each type of burner on sheet no

ADJUSTMENT OF DIFFUSER PLATE AND NOZZLE TIP

Diffuser plate is fitted to the nozzle rod guide bar end forks. Nozzle rod isinserted through the guide bar. For adjusting the distance Y between nozzletip and the diffuser plate (inner surface)

1. Loosen 4 nos. Allen screws (3) on the fixing plate.

2. Nozzle rod guide bar can be shifted forward or backward for increasing or decreasing the distance Y

3. After the adjustment, Allen screws (3) are to be tightened.

Cont -29-

PANCHAL ASSOCIATES

-29-

NOTE:

A. The distance X and Y are for nozzles type PA/DZ with the spray angle of 45/55 deg

B. If the distance is greater than the specified there may be clinker formation on the flame tube or diffuser plate. In this case distance must be reduced.

C. After the adjustment ensure that the flame and diffuser plates are in the center with respect to the nozzle tip for proper distribution of the combustion air.

D. Ensure that the ignition electrodes are not fouling in the nozzle spray.

PANCHAL ASSOCIATES

PANCHAL ASSOCIATES

PANCHAL ASSOCIATES

PANCHAL ASSOCIATES

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FLAME TUBE AND DIFFUSER PLATE ADJUSTMENT (FIG-29A)

BURNER TYPE DISTANCE X DISTANCE Ymm mm

PA-15 60 12PA-20 65 12PA-25 90 12PA-30 100 12PA-35 120 25PA-40 130 25PA-45 160 25PA-50 180 25