Installation and Operating Instructions*
Contents
1. auo SUL 100 Apoq ay 0 uo slloq uin u yorym Buu 1 oeds e o sjunow p ojow eut xoq Jeol eut pisul si 1 INq 91 0 SE uueS oui su 96 5uls adeys ul yil xoq e10W Sil pue do uo pe lsul Apog ule y JO apis 1 ay ul p lunoul si 121 ueuuotsuen au mbi i 48A09 404 uo oloud 88S 0ZH8 9 u s l yilp M e sn ag s L n s ulnq s Hg 01H8 24 smoys Buleip siy L R 0248 9148 OlLUd 1433011 3 8 4313 110 ILSYM TIOUN 34 SZuude Zumdno y yrduro ZZON owd r snyi q puey 1J9T puey 1u3rq odid ZZON qm 18814 Joye nsal re Arepuo s Apoq ur IPU puc ALN 8n d utd Yms 9 83O L 1J lonuoO ruon yg uorsu l USTH JOWJOJsUe UOUS H 21112 01094 ue JOMOTQ 11e A1epuooos 1030 omnbi4 NOlLdluoSaq SLYVd LI 91 SI XSET xap yl El c II 01 vs VL s r 35 z 36 did ap zou o Apog urew mu uy 3ulof Ajddns me Areurnd diq adid yzzou o qoss idulo adig Surydno or ne 1pKu yeur y pue rd T Sursse3 q ye souut u1 puc pol ZUNE 10 19402 yur ye q ld 10 616001 o rd L Zursse3 p odid poi 3uneoH Sud2. UN nstallation and Operating nstructions Kroll VVASTE OIL BURNER GUN MODELS BR10 BR15 AND BR20 Kroll Heaters Australia ABN 67108717451 Factory 6 4 Kirkham Road Dandenong Vic 3175 Phone 03 9791 3082 Fax 03 9791 3048 E sales kroll heaters com au W www kroll heaters com au FREECALL 1800 805 243 ENERGY OPTION VERSION INDEX Pg Introduction 2 Chapter 1 Principle of Waste Oil Burning 3 Chapter 2 What is Waste Oil 4 Chapter 3 Mounting the Burner Gun 5 Chapter 4 Oil Feed 6 4 1 Main Storage Tanks 4 2 Day Tank 4 3 Pipeline from Main Tank to Day Tank 4 4 Gravity Feed System 4 5 Pump Transfer System 4 6 Oil Feed from Day Tank to Burner Gun 4 7 Filtration 4 8 De Gassing Chapter 5 Starting and Running the Burner Gun 12 5 1 Sequence Of Functions How The Burner Works 5 2 Choosing The Correct Setting For Your Heater Or Boiler 5 3 Secondary Air 5 4 Pre Heating 5 5 Starting The Burner Chapter 6 Routine Maintenance 20 6 1 Burner Gun Filters 6 2 Water And Oil Drain 6 3 Pre Heating Rod 6 4 Nozzle Pipe Assembly 6 5 Photo Electric Cell 6 6 6 Hydraulic Coupling 64 6 7 Electrovalve 33 6 8 Cover For VVorm Gear 41 6 9 End Of Heating Season Chapter 7 Faults Possible Causes and Remedies 27 Appendix Short Maintenance Guide Exploded Parts View amp Circuits 30 Introduction Thank you for choosing a Kroll waste oil fired burner This m
3. wear and tear in your burner gun In a greenhouse heating application where the burner is working 7 days a week virtually all year round you could be looking at up to 1 500 in a worst scenario to recondition your burner gun each year In a factory or workshop heating situation you can expect to go for 4 5 or 6 years before any major wear occurs 4 3 Pipeline from Bulk Tank to Day Tank Your Kroll agent can advise you on the best arrangement for the main storage tank pipeline day tank and filtration It will vary according to the topography and layout of your site Here are some options but first a few words about the pipe itself If the pipe is exposed to risk of damage or rupture from vehicles or machinery etc it should be of galvanized steel Otherwise high grade poly or flexible petrol and oil resistant hose is fine provided it complies with local regulations Give your choice of pipe careful consideration and be vigilant Sump oil spillage or leakage is a very serious matter The risk is extremely low provided you plan your installation well and take proper precautions 4 4 Gravity Feed System If you have some fall from the main tank to day tank this works well but be aware that oil gets very thick when the temperature falls A generous flow in summer Through a 32 inch 19mm pipe can reduce to a pitiful trickle when winter comes Allow for this by using large diameter pipe up to 2 inch 50mm if it s t
4. Ducting is restricting airflow from blower fan in heater or water flow is insufficient in boiler Blower fan in heater is blocked with lint or has sucked in some paper or rubbish or Fan belt in heater is loose or broken 30 Model BR10 15 amp 20 Short Maintenance Guide ATTENTION before starting any maintenance work always disable both the main svvitch and the toggle svvitch on the burner to prevent damage to the burner amp yourself 1 Clean the oil filter s on the BULK oil supply weekly if using waste oil 2 Clean the oil filters 29 and Y strainer once a month for 229 2 monthly for the Y strainer element 3 Open the drain cock 32 once a week fortnight to release possible water 4 Clean the heat rod TVVICE PER SEASON 760 Use a scraper and wire wheel Then flush out the pre heater tank 227 to get rid of sludge at the bottom of the tank use petrol and a toothbrush 5 Clean the diffuser 15 monthly or every time the flame is not burning cleanly The diffuser does tend to carbon up so it must be cleaned The nozzle 16 should also be checked by removal amp dis assembly 6 After long operating intervals after the winter heating season for example please carry out the following operations Put some lubricating oil possibly light oil into the primary air inlet pipe 66 of the compressor Start the burner for a short while a few rotations only to allow the lubricating oil to be well distr
5. this filter by a jelly like substance which is a reaction of some unusual contaminant in the oil to the pre heating Under normal circumstances this small strainer should only need to be checked 2 or 3 times each heating season This filter is located inside the elongated hexagonal chamber 39 First remove the U shaped 6mm pipe and while holding the long hex chamber to prevent it turning unscrew the nut which holds the filter 21 Some earlier models have this small filter in a less accessible position i e inside the pre heat tank The later arrangements can be retro fitted to your burner but if you don t have it then by far the best time to inspect and clean this filter is when the heating rod is out You can get at it through the heating rod hole and this means that you don t ever have to remove the small strainer We would prefer that you did not take it out but if it s unavoidable this is how it s done It s quite awkward to remove You may have to spring the inlet pipe 38 off and on vvith care The large nut which carries the filter 39 screvvs directly into the alloy pre heat tank vvall so great care must be taken vvhen replacing it to avoid cross threading it Use a 19mm socket to remove it Apply a suitable thread sealant eg Loctite 567 before re fitting it by hand then nip it up but not over tight 6 2 WATER AND OIL DRAIN It s normal for a bit of water to accumulate in the bottom
6. 66 of the compressor 6 9 2 Start the burner for a short vvhile a fevv rotations only to allovv the lubricating oil to be vvell distributed into the rotor and blades of the compressor This will inhibit eventual corrosion and the eventual sticking of the blades in the compressor rotor as water can always be present in waste oil 27 CHAPTER 7 FAULTS POSSIBLE CAUSES AND REMED ES Goes out on flame failure at end of purge period ie magnetic valve does not click Photo electric cell 16 is picking up outside light through the vievving window or through the secondary air inlets PE cell is fauliy Faulty or dirty electrovalve 33 is allowing oil through to the nozzle during the purge period and the burner is firing up prematurely Control box 8 is faulty Purges OK but does not fire up and goes out on flame failure shortly after Mixture too lean Close air down a bit and try again No oil getting to nozzle Check that pre heat tank is full and that the pipes and magnetic valve aren t blocked Check that the hand wheel 53 has not come loose and wound back Too high water content in fuel Oil is not combustible for some reason eg contains paint thinners or a high percentage of some 100 synthetic oils Drain it out get a known sample that you re sure of and try again Oil too cold Check pre heat thermostat 62 is set to 75 C and give it time to warm up Nozzle blocked Electrodes not pos
7. It s hard to be specific about how often each maintenance procedure needs to be done because it depends on the nature dirtiness of the vvaste oil you re burning the number of hours you re running and or the number of litres you re using If you fit an hour meter to your burner and leave your volumetric pump on a fixed setting then you could establish a fairly consistent maintenance schedule But be aware that the nature of waste oil changes depending on sources storage times settling and outside temperatures If you have followed our recommendations for setting up your main storage tanks day tank and filter then you vvill have gone a ling way towards leveling out these inconsistencies The only safe vvay is to start out by doing the maintenance more often than necessary and gradually increasing your intervals according to vvhat you find Before commencing and maintenance disconnect all povver 6 1 BURNER GUN FILTERS Here we are referring only to the two filters in the burner gun itself There should be other filters between the main storage tank and the day tank and or between the day tank and the burner gun 6 1 1 LARGE OIL STRAINER 29 The large oil strainer 29 should be checked about once a month 6 1 2 SMALL STRAINER 39 PRE HEAT TANK The role of this strainer is to trap any clinker that comes away from the heating rod See Chapter 7 Section 3 On rare occasions we have experienced a blocking of
8. consume But in reality you can only run the burner at a setting which is compatible with the heater or boiler it is attached to Not all heaters and boilers are suitable for use with a waste oil burner Kroll burners run at low pressure They cannot be used successfully ona heater or boiler which is of a design that creates high back pressure because this restricts the ability of the burner to push its mixture of air and oil into the furnace Secondly the heater boiler must be designed in a way to allow access to the furnace and heat exchanger chambers or pipes in order to remove the residual dust ona regular basis ie cleaning access Assuming your heater boiler is of the low back pressure type we now need to look at the manufacturer s specified output in order to determine the most appropriate burner gun settings We recommend that you regulate your burner gun so that the heater boiler produces about 70 if its manufacturers claimed maximum output Eg the Kroll 200SZ warm air heater is fitted with the BR20 burner gun and has a maximum output of 232 kW of heat One litre of waste oil makes about 11 KW s We claim about 90 efficiency from our heaters ie about 10 of the heat that the burner gun puts into the furnace goes up the flue and is lost 90 is exchanged into the air that goes to heating your building So theoretically you could burn 23 5 litres per hour le 23 5 x 11 KW 258 KVV LESS10 efficiency loss 232 KW
9. it does not burn easily Your Kroll burner gun is designed to filter pre heat and emulsify the waste oil with air bubbles before sending it to the nozzle where it is atomized into a fine mist for reliable and efficient combustion The high furnace temperature reduces the contaminants in the vvaste oil to a grey coloured residual ash which is trapped in the furnace and heat exchanger chambers or tubes of your air heater or water boiler CHAPTER 2 What is Waste Oil VVhen vve talk about vvaste oil vve mean almost any kind of used automotive oil engine oil diff oil gearbox oil and automatic transmission oil There are some synthetic oils around which don t burn well on their own These are usually exotic high performance oils used in racing cars or specialized mining machinery so they re not usually found in large volumes High performance brake fluid is also synthetic If small amounts of synthetic oils are present in your waste oil it s not a problem They travel through and are burned up But it is the mineral base oil which provides the heat In fact waste oil has the same calorific value heating energy as conventional heating oil The contaminant to be most vigilant for is paint thinners Logically you d expect this to be volatile and dangerous but in fact paint thinners usually reacts with sump oil to form a jelly like substance which will not burn properly Your Kroll burner will not run on a mixture of sum
10. it leaves the nozzle and this creates better atomization This spiral needs to be checked once a month because it can get a build up of rubbish or carbon in the splines The spiral is symmetrical so it can go back in either way but take care that it is located properly and doesn t flip sidevvays when you are reassembling the nozzle 25 6 5 PHOTO ELECTRIC CELL 6 To understand the very important role this safety device plays see 5 1 Over time the PE cell will get a bit of soot on it which affects its ability to see the flame lt should be pulled out and wiped every two weeks or so If it shows signs of being heat affected it s probably because the heater boiler is overdue for cleaning and the excess back pressure is pushing heat back into the burner gun Because of the importance of the PE cell it vvould be vvise to keep a spare one on hand 6 6 HYDRAULIC COUPLING 64 We have fitted this so that when you disconnect the de gassing pipe it doesn t drip oil everywhere However you will need to clean both male and female parts occasionally to ensure that the opening is clear and that the coupling goes together without undue downward pressure If it leaks oil you may need to replace the O ring in the female side 6 7 ELECTROVALVE 33 These units rarely give trouble but it s wise to clean them at least once each season Take careful note when disassembling of what goes where Unplug the 3 pin plug a
11. net output However as 1 said this is a maximum situation and not sustainable on a day to day basis VVhen the heater is shiny and nevv and all clean inside you may be able to run it at 23 5 litres for a very short while But as the dust builds up inside the furnace and heat exchanger tvvo things happen Firstly this insulating layer of dust means that the heat is exchanged less efficiently so more heat goes up the flue The efficiency may drop to 80 or 7096 Because the fuel is so cheap this isn t very important VVhat is important is that as the dust builds up the alley vvays get narrovver and so it s harder for the gases the products of combustion to flow through them and on up the flue In other words as the dust builds up the BACK PRESSURE increases and the fan in the burner gun cannot push the same volume of secondary air into the furnace If you have got the volumetric pump wound up to 23 5 litres per hour then the burner will start to run very rich and make black smoke because it can t get enough air oxygen in there to allow complete combustion What all this means is that to maintain reliability and reasonable servicing intervals you need to run your heater at less than maximum In the case of the 200SZ would recommend that you run your burner set on 3 or less That relates to about sixteen litres per hour That will give you about 160 KW out put of heat If you really need more heat you c
12. this job Your Kroll agent can advise you A simple float svvitch fitted in the day tank vvill stop and start the pump to maintain the desired level in the day tank Again vve believe it is imperative that you have a safety back up system in case the float switch fails to switch off the pump We suggest a simple system From an overflow outlet near the top of your day tank excess oil would fall into a sizeable container twenty litres or so Remember that oil is coming into the day tank under pump pressure so you ll need a generous sized overflow outlet say 2 inch 50mm to match it When it gets heavy enough the container breaks the electrical connection between the float switch and the pump If your float is set up properly it s very unlikely that it will ever fail But if it does the consequences are severe enough that you simple must have a safety back up With the pump transfer system you can afford to use a smaller diameter pipe but we recommend at least one inch 25 4 6 Oil Feed from Day Tank to Burner Gun Your day tank must be higher than your burner gun to ensure a good gravity feed Fit the ball valve at the outlet point and then run a 25 mm flexible hose directly to your burner gun connecting at the pre heat tank in place of the plug 31 We recommend you use a generous length of hose that runs down to the floor and up to the burner This will enable you to take the burner on and off the heater or boiler
13. while it s on the gun To clean it thoroughly you really need to take it off the nozzle pipe This enables you to soak it in petrol or caustic soda which helps soften the carbon After scraping you can finish it off on a small wire wheel Like all the maintenance procedures we recommend they should be done before they have to be done Note that the hole in the middle of the diffuser plate is not symmetrical It is cut away more on the top to accommodate the electrodes 6 4 2 ELECTRODES A visual inspection will tell you whether the tips of the electrodes 14DX SX need cleaning It s important that neither of these electrodes is touching or too close to the diffuser plate or you ll find the spark will jump to the plate instead of between the electrodes If an electrode ever comes loose inside its ceramic casing you can tighten it up again with the nipple that the high tension lead clips on to That nipple is actually a threaded nut screwed on the end of the electrode wire itself Check the ceramic casings for cracks at least once each season and replace them when necessary If the electrodes and nozzle pipe assembly is covered in wet oil it should be disassembled and cleaned 6 4 3 NOZZLE Remove the nozzle assembly 16 with a 14mm spanner Unscrew the front part 17mm spanner from the rear part and in between you ll find a small spiral This doesn t spin itself but it causes the emulsified oil to spin as
14. 180 out and will not pump 5 3 SECONDARY AIR Efficient combustion requires the correct ratio between oil and air in your furnace This air oxygen comes into your furnace in tvvo vvays The primary air is dravvn in through the pipe 66 and mixed emulsified vvith the oil in the compressor The primary air volume is fixed for each burner It s the secondary air which must be adjusted to suit the oil volume and back pressure VVe do this by loosening the knurled lock nut on the secondary air regulator 11 and rotating this black disc to increase or decrease the size of the windows So if you wind up the oil you need to open up the secondary air also Don t be too concerned about this It s not a temperamental device There is not one sweet spot where it runs perfectly and runs badly on any other setting There s a reasonable range of settings where it runs smoothly It s hard to describe but when you have established the oil setting where you want it you should adjust the air opening so that the flame is a bright yellow or orange colour but clear around the outside so you can see the back of the furnace To get a feel for oil air ratio do this exercise While looking through the viewing window of your burner gun slowly move the secondary air regulator disc 11 through its range At a very small opening you ll see the flame get very sloppy and not clear around the outside If you leave it li
15. ET TERMINAL BLOCK FOR FLAME CONTROL EQUIPMENT MOTOR PROTECTOR BLOCK WARNING LIGHT ON marcia OFF arresto SWITCH SHUNT TERMINAL BLOCK EARTH LINE NEUTRAL WIRE BOILER THERMOSTAT ROOM THERMOSTAT FANTINI THERMOSTAT HEAT ROD LARGE r SMALL HEAT ROD D 1N4117 DIODE SOLENOID VALVE MOTOR PHOTOELECTRIC CELL IGNITION ELECTRODES IGNITION TRASFORMER IN THE ELECTRIC BOARD BURNER SOCKET 40 Wiring diagram for light heavy and used oil burners 3463 D 220 V single phase 50 Hz Flame control equipment SIEMENS Landis amp Ger LOA 24 BR20 MD T i 1 N 121 13 14 15 16 17 Ar IR EM s F 1 ur ii j T L MP TERMINAL BLOCK FOR FLAME CONTROL EQUIPMENT DS MOTOR PROTECTOR LB BLOCK WARNING LIGHT 1 ON marcia OFF arresto SWITCH MD SHUNT TERMINAL BLOCK T EARTH E LINE N NEUTRAL WIRE TC BOILER THERMOSTAT TA ROOM THERMOSTAT TR FANTINI THERMOSTAT R HEAT ROD LARGE r SMALL HEAT ROD D 1N4117 DIODE EV SOLENOID VALVE M MOTOR F PHOTOELECTRIC CELL EA IGNITION ELECTRODES TD IGNITION TRASFORMER IN THE ELECTRIC BOARD 41 SIEMENS 7 130 Oil Burner Controls LMO14 LMO24 LMO44 Microcontroller based oil burner controls for the startup supervision and control of forced draft oil bur
16. TD IGNITION TRANSFORMER F PHOTOELECTRIC CELL C CONDENSER M MOTOR I ON OFF SWITCH TR THERMOSTAT R FUELOILHEATER R SMALL HEAT ROD 30W 1N4117 DIODE LT TEMPERATURE LIMITER N NEUTRAL WIRE T EARTH L LINE Existing connections Connections to be carried out m 38 VViring diagram for light middle heavy fuel oil and used oil burners 3472 220 V single phase 50 Hz Flame control equipment SIEMENS L amp G LOA 24 BR5 10 15 ST18 7 SOCKET ST18 7 PLUG E SOLENOID VALVE MPL TERMINAL BLOCK FOR FLAME CONTROL EQUIPMENT TD IGNITION TRANSFORMER F PHOTOELECTRIC CELL C CONDENSER M MOTOR I ON OFF SWITCH TR THERMOSTAT R FUEL OIL HEATER R SMALL HEAT ROD 30W 1N4117 DIODE LT TEMPERATURE LIMITER N NEUTRAL WIRE T EARTH L LNE Existing connections wer Connections to be carried out m y ss ya n nib 39 Wiring diagram for light heavy and used oil burners 3463 D 220 V single phase 50 Hz BR20 Flame control equipment SIEMENS Landis amp Gyr LOA 24 ENERGY SAVE MP i1 2 3 4 5 6 7 10 11 12 777 P ni TIET 1rr L E D SE SC P 1 DS L LB b m 1 T x u 0 u n5 aa eo L _ V a oe j E Pr taf R iza Tel f 1 2 al 5 d e ai MD LE VL INN K ch IL 1E IN ITAIT 1 7 PIN BURNER SOCK
17. an wind it up to 3 72 which will give you about eighteen litres per hour but this means you ll have to clean it more often to prevent the back pressure building up too much If you don t know exactly what the maximum output of your heater boiler is supposed to be you can find it s limit by gradually pushing in a bigger flame When you reach the point at which the burner gun starts running to rich despite the addition of more secondary air then you ll know you ve reached the limit WARNING your heater boiler is of very low back pressure it may be possible to get away with running too big a flame This could shorten the life of your furnace The flame should never touch the sides of the furnace If it does it s highly likely that the atomized mixture will condense into wet oil and you ll get incomplete combustion and wet oil in the bottom of your furnace If the flame hits the back of the furnace but not the sides and you don t want to run at a lower setting it may be possible to erect a target of ceramic tiles or fire bricks there This will protect the back of your furnace Just by looking through the sight glass it s not always easy to tell the length of the flame Run it for a while and then carefully watch through the sight glass as you stop the burner If the back of the furnace is glowing red or orange then the flame is almost certainly hitting it IMPORTANT The figures shown on the oil consumption
18. ansparent cover of the lockout reset but ton There are 2 diagnostic choices 1 Visual diagnostics Operational status indication or diagnostics of the cause of fault 2 Interface diagnostics With the help of the interface adapter OCI400 and PC soft ware ACS400 or flue gas analyzers of different makes refer to Data Sheet N7614 Visual diagnostics In normal operation the different operating states are indicated in the form of color codes according to the color code table given below Interface diagnostics is activated by pressing the lockout reset button for at least 3 seconds refer to Data Sheet N7614 If by accident interface diagnostics has been activated in which case the slightly red light of the signal lamp flickers it can be deactivated by pressing again the lockout re set button for at least 3 seconds The instant of switching over is indicated by a yellow light pulse Operating position Operating position Visual diagnostics Interface diagnostics PC analyzer Color code table During startup status indication takes place according to the following table 7130z01e 0602 indication Color code table for multicolor signal lamp LED Status Color Waiting time tw other waiting states Q Off Oil preheater on waiting time tw L e Yellovv Ignition phase ignition controlled eOeOeOeOeO
19. anual will explain how to install operate and maintain your burner Kroll burners can be fitted to air furnaces or heaters which push out warm air or to boilers to produce hot water It s important that you also read the separate manual about that apparatus in conjunction with this burner manual When you burn waste oil in a Kroll burner provided you have it adjusted correctly and attached it to a compatible heater or boiler it will run cleanly and reliably BUT in exchange for being able to run on this free or inexpensive fuel you have to put up with inconvenience of some extra maintenance compared to using gas heating oil or electricity If you are not prepared to carry out this extra maintenance then to be blunt you have bought the wrong heater Generally speaking the savings on running costs are so great that this effort and inconvenience on your part are well worthwhile VVe believe that in order to look after your burner you need to have a good understanding of how it works So please take the trouble to read through this manual We cannot look after your Kroll for you We can only make it as easy as possible for you to do it yourself by giving you the information you need Please be patient Read all the way through this manual and digest it before attempting to start your burner CHAPTER 1 Principle of Waste Oil Burning VVaste oil has a high flash point compared to conventional heating oil This means
20. chart are only a rough guide Oil viscosities can vary greatly You may need to use a lower setting with thin oil The other important variable is wear on the parts in the metering pump specifically items 47 Ring 48 Rod and 46 Piston When your burner is new a hand wheel setting of say 2 1 2 on your 2 give you a consumption of about 14 litres per hour However 6 months later in the case Of greenhouse heating after 15 000 litres have passed through your burner these parts will have vvorn a bit and be a bit sloppy This means that on the same setting of 2 1 2 you may now be burning more like 17 or 08 litres per hour and producing a flame vvhich is too big for your heater or boller to cope vvith You may have to turn the wheel down to 1 or 2 to get the right sized flame again Taken to extremes you can finish up with the wheel on zero yet still have a big flame Of the three parts the ring wears fastest It is also the cheapest part to replace so we recommend that it be replaced before it wears too much This will increase the life of the parts it engages vvith It is relatively easy to remove and inspect Firstly switch off the power at the wall Then turn the oil off at the day tank and drain most of the oil from your burner gun Now remove the hand wheel then the four screvvs retaining item 50 Take care not to lose the small copper vvashers under each screvv They re very important to preven
21. e Flashing yellow Operation flame o k Lo cssspuyasasuwsssasawsasysaysssaspassha Green Operation flame not ok ROROnOnDORno Flashing green Extraneous light on burner startup DALALALALA Green red Undervoltage Yellovv red Fault alarm E L E AER Red Error code output refer to Error code ta AO AO AO AO Flashing red ble AQ nterface diagnostics A A A A A A A A Red flicker light Legend Steady on A Red Off Yellow O Green 9 13 Siemens Building Technologies CC1N7130en HVAC Products 12 12 2005 44 45
22. e It will purge for a bit longer than normal and then shut down on flame failure ie the red light which is also the reset button comes on on the control box When the burner goes off on flame failure at the end of the purge period it s because the PE cell can see some light The most likely cause of this is strong sunlight shining through the viewing glass The PE cell is very sensitive and thinks it can see a flame Some tape over the viewing glass will fix this problem Assuming that all is in order at the end of the purge period ie no light visible the PE cell sends a message to the control box which then sends power to the three way electrovalve 33 During the purge up to this point the warm oil in the pre heating tank is being pumped around in a circle ie it is drawn out of the pre heating tank via the inlet pipe 38 into the metering pump 57 goes along the pipe 55 into the electrovalve 33 out the top and back along the other pipe 61 and falls back into the pre heating tank via the de gassing T piece 64 At the end of the purge the electrovalve closes off the top outlet and opens the lower one to a small elbovv that leads directly into the compressor This is where the warm oil is mixed or emulsified with the primary air and sent on to the nozzle The primary air is dravvn in through the copper pipe 66 VVhen this mixture of vvarm oil and air bubbles reaches the nozzle it comes o
23. he burner gun or a blocked filter then we suggest you run it initially set at 1 on the hand wheel At this oil setting you ll only need a fairly small opening of the secondary air regulator 11 a window opening of about 5mm or 6mm 5 5 2 STARTING By now you have fitted the de gassing pipe primed the gun with oil allowed it to heat up to 75 C set your hand wheel on 1 and set your secondary air regulator at a small opening Throw the toggle switch to start or ON or wind the room thermostat up if you have wired one in and the burner will start to purge After about 10 seconds you ll hear the click of the electrovalve 33 and your burner should fire up within two or three seconds 5 5 3 INCREASING FLAME SIZE When the burner has been running on a small flame in a stable manner for five minutes or so you can gradually wind it up to your desired setting see table 5 1 2 5 5 4 AUTOMATIC RESTART If the burner is running and the flame dies for some reason eg lack of oil instead of shutting down on flame failure ten seconds after the flame disappears the burner control box is programmed to attempt one restart ie ten seconds after losing sight of the flame it goes back to the purge period purges for about ten seconds the magnetic valve clicks open again and this time if it doesn t fire up within ten seconds it shuts down on flame failure The red flame failure light comes on and
24. ibuted into the rotor and blades of the compressor This will inhibit eventual corrosion and the eventual sticking of the blades in the compressor rotor as water may be always present in waste oil STARTING THE BURNERI If restarting the burner after a long period of burner inactivity turn the main 240 VAC supply switch ON first then wait for about 15 minutes until the oil is heated and then turn the operating toggle switch 8a of the burner on The burner will now work correctly with hot oil This short guide should be read together with Chapter 6 31 1oop p Bulu e ul jejow 8 pisul ap suolo uuoo 6211 09 ay pue g ueuomnuoa ji uojnjo j eut 100 Apoq Jeng 2y o uo slloq WN l U9IUA Buu s oeds e o sjunow Tel o oul eut xoq fel ul au pisul p ye ol si il 1nq 51 01 SE oui 51 96 aus JQ adeys ul yil So Si pue doy uo peajsul Apoq ujew y apis out ul p lunou si Z ueuuosuen eut amb W c L 49A09 WOU uo OJOUd oeug u u e snf un6 s ulnq S Hg 01H8 24 smoys siy 0248 SLUd 0148 1300 8 Gauls 110 ILSYM TIO 32 Z 33 Appendix oop pebuly e ulu xoq je ow E p su ae suollo99uuo2 feok l au pue g
25. itioned properly or need cleaning Diffuser plate 15 too dirty Too much back pressure in heater or boiler Overdue for cleaning Flue blocked Perhaps the hat has fallen down Burner fires up okay but then shuts down on flame failure soon after Check PE cell for soot Perhaps it can t see the flame PE cell faulty Control box faulty 28 Burner fires up okay runs for a while but then starts to run very badly pulsating and making black or grey smoke Mixture too rich Open air up a bit Wet oil in furnace When it warms up it vapourises and erupts into a ball of flame Remove burner gun and dry out the furnace as much as possible with rags If the wet oil is sticky and stubborn soak it with some diesel of degreaser and then dry it out DO NOT USE PETROL If furnace is hot let it cool down before cleaning and attempting to re start If fire bricks are used in the furnace let them cool down remove them clean as well as possible and refit them Turn the gun down to a small flame ie set metering knob to 1 and close the air down accordingly Fire it up adjust the air a bit if necessary and let it run on a small flame until it dries itself out maybe half an hour or so If even on a small flame the furnace erupts again and the burner starts pulsating switch it off wait five minutes and try again When it s been running with a stable flame for a while you can ease the flame back up to your normal set
26. ke that for a few minutes it will start to run very rich and blow black smoke start pulsating and run very roughly When that just starts to happen gradually open up the air and you ll see the flame tighten up and become clear around the edge As you keep opening the air it will start to run to lean The flame gets very crisp and white smoke belches out the flue and starts to leak out around the burner mount If you go too far the flame will die Your best and easiest guide is what you see at the top of the flue at least initially After a while you ll learn to read the flame quite well BASICALLY IF YOU RE GETTING GREY OR BLACK SMOKE IT S TOO RICH AND NEEDS MORE AIR IF YOU RE GETTING WHITE SMOKE IT S TOO LEAN AND YOU NEED TO CLOSE THE AIR DOWN A BIT If there s no smoke at all then you re pretty close to the mark If in doubt favour setting a tiny bit on the rich side If it s too lean it will still run okay but may be a reluctant starter Like a car they always start better if they re a bit rich If it is reluctant to start the first thing to do if you re sure you ve got the oil at the nozzle and it s had time to pre heat properly is close the air down a bit and try again 5 4 PRE HEATING When you re starting from scratch ie the burner gun and oil are cold you ll need to allow 15 to 20 minutes to ensure that the oil in the pre heat tank is up to temperature If you wrap your ha
27. nd around the bottom of the pre heat tank you ll get a feel for how hot it gets The waste oil must heat up to 80 C for automotive waste oil If you remove the cover 63 you ll see the end of the heating rod 60 and the thermostat 62 that controls it DANGER Always disconnect electricity to the burner gun before removing this cover This means disconnecting the seven pin plug 9 or switching off the power to the gun at the heater boiler NB even when the toggle switch is in the STOP position there is still power to the pre heating rod and thermostat Remove the cover 63 carefully because it s still attached by the wires running through it Waste oil has a quite high flash point so it s necessary to pre heat it to make it burn cleanly If you ever come across some waste oil that has a high percentage of diesel fuel or kerosene in it it s quite ok to use it but you may need to turn the pre heat thermostat down to 30 or 40 C because the flash point of diesel fuel is much lower than waste oil There s a chance that it it s too hot the diesel could arrive at the nozzle as a gas instead of a liquid and then you d get unstable running and small explosions or pulsations 5 5 STARTING THE BURNER Finally after all this rigmarole we are ready to fire up the burner 5 5 1 SETTING OF THE HAND WHEEL If your starting the burner for the first time or if you have just sorted out a problem such as water in t
28. nd take the electrovalve off the burner gun by unscrewing the three small pipes attached to it Undo the top nut and slip the magnetic block ie the energizer off the post Unscrew the four small Phillips head screws to reveal the plunger and spring Wash everything in petrol blow it out with compressed air if available and reassemble 6 8 COVER FOR WORM GEAR 41 We have fitted an adjustable grub screw since 96 to this cover The worm drive gear because of the spiral drive action pushes against the steel ball which is fixed to the end of the grub screw Over time the steel ball wears which allows the worm gear to creep away from the compressor rotor which drives it This reduces the contact area between the tongue and groove drive connection of the compressor rotor and worm drive and causes more rapid wear to both parts Loosen the lock nut and turn the grub screw in to take up the slack being careful not to overdo it and put too much pressure on the rotor If you do it while the burner is running you can get a good feel for the point at which you re starting to put a bit of load on the compressor rotor then just back the grub screw off an eighth of a turn and retighten the lock nut 26 6 9 END OF HEATING SEASON After long operating intervals after the heating season for example carry out the following operations 6 9 1 Put some lubricating oil possibly light oil into the primary air inlet pipe
29. ners in intermittent operation Standard versions with an oil throughput up to 30 kg h special versions above 30 kg h The LMO14 LMO24 LMO44 and this Data Sheet are intended for use by OEMs which integrate the burner controls in their products Use features Use The LMO are designed for the startup and supervision of 1 or 2 stage forced draft oil burners in intermittent operation Yellovv burning flames are supervised with photoresis tive detectors QRB blue burning flames with blue flame detectors QRC n terms of housing dimensions electrical connections and flame detectors the LMO are identical with the LOA oil burner controls Oil burners with fans to EN 267 Burner controls for use with atomization oil burners of monoblock design to EN 230 1044 for use with stationary direct fired air heaters General features Undervoltage detection Electrical remote reset Bridging contact for oil preheater Monitoring of time for oil preheater Accurate and reproducible control sequence thanks to digital signal handling Controlled intermittent operation after 24 hours of continuous operation Limitation of the number of repetitions Multicolor indication of fault status and operational status messages CC1N7130en Siemens Building Technologies 12 12 2005 HVAC Products 42 Function Preconditions for startup Undervoltage Time supervision oil preheater Controlled intermittent operati
30. ng further unscrevving you must take some steps to avoid destroying the heating rod You could try rotating it carefully back and forth in the little movement that is available to try to dislodge some of the carbon You ll hear it crunching If that is unsuccessful you will need to pour some caustic soda SOLUTION INTO THE PRE HEAT TANK Remove the de gassing T piece 64 and pour it in through the top of the pre heat tank after refitting any plugs filters you may have already removed Let this caustic soda solution soften up the carbon for a vvhile before you try again If despite these methods you feel you are unable to remove the heating rod without damaging it do not proceed until you have contacted your Kroll agent He may be able to arrange for you to have a replacement heating rod on hand so that if yours is damaged when you re attempt to remove it your burner gun will not be out of service Once the rod is out you can remove the carbon There s no easy vvay to do this that we re aware of You just have to scrape away at it and finish it off on a vvire wheel WHILE THE HEATING ROD AND THE LARGE STRAINER ARE OUT IT IS VERY IMPORTANT THAT YOU FLUSH OUT THE PRE HEAT TANK This sludgy material is made up of carbon that has flaked off the heating rod and contaminants that have settled out of the oil in both the upper and lower galleries of the pre heat tank This can be done using petrol or diesel and a toothbr
31. of the pre heat tank It should be drained off through the drain cock 32 at least twice a week If you want to completely drain the pre heat tank remove the large strainer 29 The drain cock 32 is ineffective for this purpose because of its small aperture and internal galleries in the pre heat tank 6 3 PRE HEATING ROD Over time a tough coating of carbon or clinker will build up on this rod 60 IT IS ABSOLUTELY IMPERATIVE THAT IT BE REMOVED AND CLEANED AT LEAST TWICE EACH SEASON As the clinker builds up the rod works less efficiently If the coating is too big it is very difficult to remove the rod for cleaning To remove the heating rod firstly disconnect and remove the thermostat 62 from it s pocket Take note of where the wires go so you can refit them correctly Write it down Please do not try to unscrew the heating rod with a shifting spanner It s important that you equip yourself with a 32mm RING spanner A ring spanner is preferable to a socket because you can see that the whole heating rod is turning and not just the hex nut 22 The heating element is bonded to the nut If the carbon has built up on the element so much that it cannot turn inside the pre heat tank then applying excessive pressure will cause that bond between the element and the nut to break f the heating rod starts to unscrevv as it should but then you can see that the build up of carbon on the element is preventi
32. on Control sequence in the event of fault Resetting the burner control Ignition program with LMO14 113B2 and LMO24 113B2 Limitation of repetitions 8 3 e Burner control is reset All contacts in the line are closed and there is demand for heat e No undervoltage e Flame detector is darkened and there is no extraneous light e Safety shutdown from the operating position takes place should mains voltage drop below about AC 165 V UN AC 230 V e Restart is initiated when mains voltage exceeds about AC 175 V UN AC 230 V If the oil preheater s release contact does not close within 10 minutes the burner control will initiate lockout After no more than 24 hours of continuous operation the burner control will initiate automatic controlled shutdown followed by a restart If lockout occurs the outputs for the fuel valves the burner motor and the ignition equipment will immediately be deactivated lt 1 second Cause Response Mains failure Restart Voltage has fallen below the undervoltage Restart threshold Extraneous light during t1 Lockout at the end of t1 Extraneous light during tw Prevention of startup lockout after 40 sec onds at the latest No flame at the end of TSA Lockout at the end of TSA Loss of flame during operation Max 3 repetitions followed by lockout Oil preheater s release contact does not Lockout close within 10 minutes In
33. p oil and paint thinners Fortunately thinners have a fairly distinctive smell If you re collecting your own oil you ought to be able to detect and avoid it If you re buying your oil from a waste merchant it is important that you tell him that paint thinners is absolutely unacceptable It will cause rapid damage to your burner gun CHAPTER 3 Mounting the Burner Gun Insert the blast tube 12 into the furnace opening and mount it using the pair of C shaped alloy clamps and insulating gaskets provided The gaskets should be offset to the clamps so the gaps do not coincide The furnace opening should not be much bigger than the bell on the blast tube t is preferable if it s smaller provided you can poke the blast tube through from the inside The drip hole in the bell should always face down If possible locate the blast tube so that the drip hole is in the furnace itself rather that in the neck of the furnace Have a qualified electrician wire up the seven pin plug 9 to your air heater boiler CHAPTER A Oil Feed This is one of the most important chapters in this manual 4 1 Main Storage Tanks The great appeal of a Kroll burner is its very lovv running cost But this is also its Achilles Heel The fuel is cheap because it s dirty Your Kroll burner is very tolerant It will run on just about any kind of waste automotive oil but it will not run on water or sludge The best way to eliminate f
34. pecially if it should flow into a creek or dam We recommend the building of a bund wall This can be as simple as an earth dam around your tank or it can be constructed vvith a concrete slab and blocks painted with a sealant on the inside You should check with your local authorities or your Kroll agent to see whether such a precaution is mandatory or not b d Bulk Tank 51 G Fitter EZ Bulk Tank T rin ON OFF L SE Degassing Pipe L L I Header Tank Burner Gun 4 2 Day Tank A certain amount of fine silt and metallic dust will stay suspended in the oil This doesn t affect reliability in the short term because it passes easily through the burner gun Hovvever the fuel is also the lubricant for the moving parts inside the burner gun and all this abrasive material can cause premature wear A tank of between fifty and one thousand litres called a day tank or header tank should be located near your heater and fed from your main storage tank The standard domestic heating oil tank is ideal It s about 400 litres and can usually be found just by asking around because many homes have switched to gas heating In conjunction with a good filter this decanting of the waste oil eliminates much of the abrasive material and reduces the ash build up in your heater boiler Even after settling and filtration of your oil you can still expect a certain amount of
35. pol une u SLO dund 3uu ui ulsnoH zi se owes OSCH 0 duind Zuu adig mu pojnuy puEH suuds L9 99 KH v9 9 09 19 09 6S g LS 9 s ys ES cs NOLL dIO 20 SLYVd L X 61 X 9 1898 HO pod rmu qoy Uuoddng JoyseH YIM POY 911109999 10 SUY uojsid 10 04 dund Sun ti 10 101031 232 WIO M y yser 8 1 224 eg Jeos WIOM 19A02 Joquivy feuosex H yur yeoy oid ews Inu pue Joureds Ho duind did yoju L X 9 X 8 ess HO duind Joj yeas aaog z 15 os er 8b Ly oF Sp yr r Or 6 d Le d yoysey dund 19409 puq ABM 9IIY L yooo uteq snd Josey yur yeoy oid osse ioure ns HO ATPA SLA mss lq yur Jeoy s1g Jour 0559 4 2 peiq 100 10301 Josso1dwi0d 1ioss idurto5 10 yser ajd pu soss sdulo2 L x ZZ X 01 10101 08589 10 02 10 yeas 10301 10ss 1du109 ssog St ve SS TE 16 UC ez 8 LT 92 ST yc TE Ic oz 37 3472 BR5 10 15 VViring diagram for light middle heavy fuel oil and used oil burners 220 V single phase 50 Hz Flame control equipment SIEMENS L amp G LOA 24 ENERGY SAVE OPTIONED ST18 7 SOCKET ST18 7 PLUG E SOLENOID VALVE MPL TERMINAL BLOCK FOR FLAME CONTROL EQUIPMENT
36. raveling 30 metres or more having only gentle curves not right angle bends and if possible run inside the building or underground where it s not so cold If the distance from your storage tank to your day tank is less than five metres 1 inch 25mm pipe is adequate provided you have at least a one metre fall Of course you have to control the flow of oil into the day tank A conventional full flovv float valve eg Philmac brand can be mounted in the day tank If it has rubber O rings they should be replaced with a neoprene type which is unaffected by oil Float valves can leak if some grit gets under the seat You need a safety back up You could fit an electric motorized valve or solenold valve to the main pipe activated by a float level svvitch mounted in the day tank above the float valve Or it can be very simple From an overflovv outlet near the top of your day tank excess oil would fall into a sizeable container twenty litres or so When it gets heavy enough the container pulls on the lever of a ball valve thereby closing off the main pipe see diagram belovv ovartiow pipo Floal Valva 1 E 1 ai nu a Day Tank 20 Litre bucket Day tank with gravity feed from storage tanks showing safety shut off valve in case of overflow 4 5 Pump Transfer System If you cannot gravity feed to the tank you will have to pump the oil There are a variety of pumps available for
37. s activated without oil around it for more than about 10 minutes it may suffer damage Open the ball valve at the day tank outlet and watch the oil flow down the 1 TMP hose and into the gun After a short delay while it fills the pre heat tank of the gun the oil will appear in the de gassing pipe and climb up till it has reached the same height as the oil level in the day tank If you have a filter on the outlet of the day tank it may be necessary to bleed any air out this filter as it fills to prevent an air lock 5 1 2 THE VOLUMETRIC PUMP amp OIL CONSUMPTION The Hand Wheel The amount of oil your burner gun will use is determined by where you set the hand wheel 53 This chart shows the approximate consumption for the BR10 15 and 20 Model Position on Hand Wheel 1 2 3 4 5 6 BR 5 l hr 2 3 4 5 5 5 5 5 BR 10 Ihr 4 6 8 10 11 11 BR 15 Ihr 6 11 15 17 18 18 BR 20 l hr 5 12 16 20 23 23 The higher the setting the bigger the flame To adjust the hand wheel loosen the knurled lock nut line up the desired position of the hand wheel with the index mark ie the indentation on top of the volumetric 14 pump and tighten it up again Eg on a BR10 if you set the hand vvheel about half way between 1 and 2 it will use approximately five litres per hour 5 2 CHOOSING THE CORRECT SETTING FOR YOUR HEATER OR BOILER In theory the hand wheel determines how much oil the gun will
38. t oil leaks Item 50 will come away with the eccentric rod 48 and ring 47 attached When they re new the ring is a nice snug fit on the rod and in the piston If the new ring is still quite sloppy on the rod then you ll need a new rod as well Look for wear on the outside of the ring also On BR10 and BR15 where there is less contact area you can turn the ring over to get a bit more life out of it You can inspect the piston for wear without having to remove it You ll see some small crescent shaped vvear marks vvhere it engages vvith the ring Usually you can vvear out 2 or 3 rings before you have to replace the rod and piston 5 2 1 REPLACING THE PISTON To replace the piston 46 you need to take out the metering pump rotor 45 Firstly remove covers 41 and 34 and withdraw the worn gear 44 by grabbing it vvith pliers The bevel gear 36 is screvved onto the threaded end of the metering pump rotor Your Kroll agent can lend or sell you the special tools required to unscrevv the bevel gear Or you may get avvay vvith using some pointy nose or circlip pliers You ll have to hold the other end of the metering pump rotor by inserting a suitably sized square shaped tool into the cut away of the piston Take care not to burr the edge of the piston VERY IMPORTANT Youll notice on one side of the rod there is stamped on O This O must be facing up when you refit the hand wheel or your metering pump will be
39. the event of lockout the LMO remains locked and the red signal lamp LED will light up The burner control can immediately be reset This state is also maintained in the case of mains failure When lockout occurs the burner control can immediately be reset To do this press the lockout reset button for about 1 second lt 3 seconds The LMO can only be reset when all contacts in the line are closed and when there is no undervoltage If the flame is lost during TSA the burner will be reignited but only until the end of TSAmax This means that several ignition attempts can be made during TSA re fer to Control sequence If the flame is lost during operation a maximum of 3 repetitions can be made If the flame is lost for the fourth time during operation the burner will initiate lockout The repetition count is restarted each time controlled switching on by R takes place Siemens Building Technologies HVAC Products CC1N7130en 12 12 2005 43 Operation display diagnostics Operation Operational status Lockout reset button EK is the key operating element for resetting the burner control and for activating deactivating the diagnostic func 71302050700 tions g Red The multicolor signal lamp LED in the lockout reset button is the key 8 Yellov indicating element for both visual diagnostics and interface diagnostics 8 Green LED Both EK and LED are located under the tr
40. tings What causes wet oil in the furnace Possibly a blocked filter or too much back pressure or an empty day tank The burner is running but as the filter blocks it gradually starves for oil It struggles on running badly before it dies and during this time the poor combustion means unburnt oil accumulates If you were near the heater when it was struggling you d notice and do something But if it happens in the middle of the night before you can fire it up again you need to fix the original cause of the wet oil Flame too big for furnace Too much wear in burner gun specifically in the compressor If the compressor liner 26 and rotor blades 25 are too worn Your burner will not atomize properly Instead of getting a nice fine mist at the nozzle you could be getting large droplets of oil which do not burn well This sort of wear does not occur overnight so there is usually plenty of warning If your gun is noisy and is not burning well contact your Kroll agent before winter Don t ignore the signs and leave it till the last minute Pre heat tank is hot but burner won t even start to purge Thermal overload for burner motor BR20 only has tripped out reset in black metal box Check flame failure light Push to reset On BR20 it s in the black metal box with the hinged door 29 e Check room thermostat e Check safety thermostat in heater boiler lt might be overheating because Flame is too big
41. uel related problems is to have a good storage tank arrangement We strongly discourage feeding your burner directly from 205 litre drums even as a temporary measure We recommend you put in two proper storage tanks of between five thousand and twenty thousand litres capacity depending on your expected consumption Given time the water and sludge will settle to the bottom It is ABSOLUTELY ESSENTIAL that the oil feed outlet from your tank is well above the lowest point We recommend that at least 10 of the tank s capacity be below the outlet You should have another outlet at the lowest point to drain off accumulated water and sludge once or twice each year If possible locate this drain at the opposite end to the feed outlet and slope the tank that way slightly It is very important to have two storage tanks to allow settling time Most waste oil has moisture and dirt suspended in it If you can let it settle for 3 or 4 weeks a lot of the rubbish will fall to the bottom Every time you get a new delivery of oil not only does it have its own suspended contaminants but when you pump it into your tank it stirs up some of the sludge that has settled out of previous deliveries With two tanks you can be running one while the other is settling We recommend you fill both tanks during Summer because the longer it sits there the better it gets The consequences of spilling a large amount of sump oil are quite horrific es
42. use a transparent or semi transparent PVC hose that can handle warm oil up to about 50 C It s much better if you can see the oil level in this de gassing pipe 12 Chapter 5 Starting and Running the Burner Gun Before attempting to fire up the burner gun it is important that you have a reasonable understanding of hovv it vvorks particularly the sequence of the various functions 5 1 SEQUENCE OF FUNCTIONS How the Burner Works When you throw the toggle switch or the thermostat calls for heat the burner will not fire up straight avvay First it goes through a PURGE period The purpose of this s to remove un burnt fuel amp vapour in the furnace t does this by blovving air into the furnace from the secondary air fan 5 This dilutes the un burnt fuel and then the electrodes 14 ignite the weakened mixture You ll get a small poof as this happens The purge goes on for about 10 seconds so the fan can push out the gases You ll always get a small amount of smoke out of the flue at this time During the purge period the photo electric PE cell 6 which is located in a small plastic socket on the right hand side of the burner gun barrel is checking to see that there is no light ie no flame present After the initial poof and subsequent purging there should be no fuel present and hence no flame If there is a flame present then the PE cell will not allow the burner gun to proceed to the firing up stag
43. ush or similar small brush It s a bit awkward to get at but if you ignore it it will cause you grief later on 6 4 NOZZLE PIPE ASSEMBLY It s very important that the components are mounted according to the specifications If the clearances between the nozzle diffuser plate and electrodes are not correct the burner may not start and run properly This is not to say that you have to use vernier calipers to set it Or that if it s out a whisker it won t fire up It s not that critical Use a ruler initially to ensure that the clearances are about right After a while you ll be able to do it by eye See image next page 23 24 BR 10 15 and 20 Layout of nozzle pipe assembly shovving relative clearances in millimetres betvveen electrodes nozzle and diffuser plate 6 4 1 DIFFUSER PLATE By looking through the sight glass when the burner is running you can monitor the build up of carbon on the diffuser plate 15 It s important that the vents are not clogged You should not let it build up too much because even though it may accumulate over a week or two it reaches a certain point and then the build up and efficient combustion can accelerate rapidly There s no easy way to clean it You just have to scrape it off We have had some success with spraying it with oven cleaner and leaving it sit for a while This softens the carbon a bit and enables you to do an interim job
44. ut as a fine spray atomization The secondary air which is rushing down the black blast tube 12 and swirling when it passes through and around the vvindmill shaped disc called the diffuser plate 15 controls the shape of the spray of this atomized oil and supplies the oxygen that enables it to be ignited by the electrodes 14 which are throvving a 13 strong spark throughout this whole purge and firing up process The spark stops about 14 seconds after the flame starts Listen carefully for the click of the electrovalve 33 and a slight change in note of the burner which signals the end of the purge period Sometimes the click is so soft you need to place your finger on the electrovalve to feel it click The burner gun should fire up vvithin 2 or 3 seconds of the click At the end of the purge period The PE cell 6 which during the purge period was checking to make sure there vvas NO light present reverses its role t is novv checking to make sure there is a light present and if it doesn t see one vvithin about 10 seconds it will shut the burner down on flame failure Now that you have an understanding of the sequence of functions we can go back to the start up procedure 5 1 1 PRIMING THE BURNER GUN You cannot attempt to fire up the burner gun until it is primed i e inlet pipe and most importantly he pre heating tank are full of oil Also if the pre heating rod 50 i
45. without having to disconnect the oil line We normally use a transparent flexible petrol and oil resistant PVC hose eg Nylex TMP That stands for transparent multi purpose and the hose has a thin red line on it It s important that 90 elbows are used at each end If the hose is fitted in a horizontal position it will eventually sag and kink 4 7 Filtration You must have some form of filtration in your oil supply system Consult your Kroll agent for advice on the best type and size to suit your needs 100 Micron is a good filter element size 11 4 8 De Gassing As the oil heats up in the pre heating tank it gives off small amounts of gases and vvater vapour Also as it heats up the oil expands We have provided a short length of 1 2 inch copper pipe attached to a hydraulic coupling on top of the pre heating tank 64 to vent these gasses off We want you to fit a length of 1 2 inch hose to this run it up to the roof of the shed or at least higher than your day tank The oil will rise in the de gassing pipe to the same level as the tank that is feeding it It s normal practice to leave the pre heating on all the time during winter This way your burner will always be ready to fire up If you switch the power off to the burner you ll have to wait about ten or fifteen minutes each time to allow the oil to heat up before you can start it It is most unlikely to start reliably with cold oil It s best to
46. you have to wait about fifty seconds before you can reset the flame failure lock out by pushing on the red illuminated button and trying again NOTE It will not automatically attempt a restart if it fails to fire up on an initial start up It only does that if the PE cell loses sight of light while it s actually running 5 5 5 FLAME FAILURE If it fails to fire up after three or four attempts it s no good just repeatedly pushing the flame failure reset button You have to look for the reason and most importantly you need to take the burner gun off the heater boiler and look to see if it s dumped some wet oil in the furnace If it has this needs to be removed by wiping it out with a rag See faults possible causes and remedies If you don t wipe put most of the oil when you eventually find the fault and get the burner fired up very soon afterwards that wet oil will heat up and start vapourising and the gases ignite into a ball of flame and the burner gun starts backfiring It s a bit scary the first time it happens with vibration and smoke coming out around the mounting bracket If it s only fairly sedate let it run for a while on a small flame say 1 on the hand wheel and it will dry out that wet oil and start running smoothly But if it s a bit violent you must switch off the burner gun remove it and dry out the wet oil with a rag before attempting another start up 20 CHAPTER 6 Routine Maintenance
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