PROCESS BURNER DIVISION - Lanemark Burners/Product Manuals - English/TX... · PN 72001 OCT 2000 PROCESS BURNER DIVISION INSTALLATION, COMMISSIONING AND MAINTENANCE MANUAL The information

PN 72001 OCT 2000

PROCESS BURNER DIVIS ION

INSTALLAT ION, COMMISS IONING AND MAINTENANCE MANUAL

The information contained in this manual is advisory and in general terms only and does not constitute a legal liability on Lanemark International Ltd. This burner is protected by patents. Lanemark International Ltd reserve the right to supply equipment to their latest specification.

T X T A N K H E A T I N G S Y S T E M J O B N o : J - - - - -

C U S T O M E R :

E N D U S E R : B U R N E R S :

LANEMARK INTERNATIONAL TX BURNER MANUAL CONTENTS

Page 1

SECTION DESCRIPTION PAGE

1 GENERAL DESIGN 11 Brief burner specification 21 Shipping contents 21 Construction standards 21 General design considerations 21 Installation 21 Fig 1 TX General dimensions 31 Fig 2 TX Exploded view 41 Fig 3 General arrangement of installation 51 Heat exchanger design 61 Fan exhaust damper 61 Flue pipe from several dampers to a common exhaust fan 61 Exhaust flue fan 61 Flue systems 61 Temperature controllers 71 Liquid level protection 71 Ventilation systems 71 Protection of burner systems 71 Electrical supply 81 Gas supply general 81 Gas supply – natural gas 81 Gas supply – propane gas 81 Fig 4 Flue exhaust damper 91 Fig 5 General arrangement of exhaust fan 101 Fig 5 Table of dimensions of fan 11

2 HEAT EXCHANGER DESIGN 12 Heat exchanger design 22 Heat exchanger design drawings 22 Fig 1 Flange and plate mounted heat exchangers 32 Fig 2 Heat exchanger flange mounting detail 42 Fig 3 Heat exchanger support 42 Heat exchanger design drawings ( only included if specific drawings made for the Job ) 5 →→→→

3 CONTROL PANEL DESIGN 13 Control panel 23 Interface wiring diagram 23 Panel internal wiring diagram 23 Fig 1 Control panel 33 Fig 2 Electrical interface wiring diagram and control panel internal wiring diagram 4 →→→→

4 TEMPERATURE CONTROL DESIGN 14 Temperature control 24 Wiring / setting / programming temperature controllers 24 Temperature sensors 24 Data sheets on controls and sensors ( only included if supplied with the Job) 3 →→→→

5 OTHER CONTROLS DESIGN 15 Other controls 25 Programming other controls 25 Programming / setting other controls 25 Installing / wiring other controls 25 Data sheets on other controls ( only included if supplied with the Job) 3 →→→→

LANEMARK INTERNATIONAL TX BURNER MANUAL CONTENTS

Page 2

SECTION DESCRIPTION PAGE

6 GAS TRAIN DESIGN 16 Gas trains 26 Wiring gas trains 26 Drawings of gas trains 26 Setting / adjusting gas valves 26 Gas train drawing ( only included if supplied with a Job) 3 →→→→6 Gas valve data sheets ( only included if supplied with a Job) 4 →→→→

7 INSTALLATION 17 Fitting the heat exchanger 27 Fitting burner / control panel / gas train / flue damper / 6 mm pressure sensing pipe 27 Making gas / electrical / temperature / modulating / liquid level / over temperature

control connections3

7 TX Burner installation check list 4

8 COMMISSIONING 18 Precommissioning control panel / fan / gas 28 Dry run of burner 38 Commissioning combustion 48

orFig 1 Natural gas pressure against output graphFig 2 Propane gas pressure against output graph

6

8 Commissioning report form 7

9 MAINTENANCE 19 Cleaning and maintenance 29 Cleaning burner head / fan gas train / controls 29 Fig 1 Burner head and electrodes 39 Fig 2a Electrode setting TX15 to TX40 49 Fig 2b Electrode setting TX60 4

10 FAULT FINDING 110 Fault finding general 210 Fault finding temperature control 210 Fault finding gas valves 210 Fault finding burner programmer 3

11 COMPONENT REPLACEMENT 111 Replacing probes / burner head / fan impeller / valve coils / gas valves 211 Replacing burner programmer /transformer / mod.motor / 3 way valve / pressure switch 3

12 SPECIAL COMPONENTS 112 Data sheets / instructions ( only included if supplied with a Job) 2 →→→→

13 RECOMMENDED SPARES 113 Recommended spares list ( only included if supplied with a Job) 2 →→→→

14 HEALTH AND SAFETY 114 Health and safety data sheet 214 Fluing TX burners inside buildings 3

15 NOTES 115 Notes 2

LANEMARK INTERNATIONAL TX BURNER MANUAL DATA PLATES

Data Plates Page 3

If this manual was sent out with an actual burner ( or several burners built to the same specification ) aduplicate Burner Data Plate will be included on to this page. This will give the actual burner :-

Serial NumbersGas Type ( Natural or Propane )Electrical and Gas Train SpecificationBurner Head Pressure SettingFan Motor Supply Voltage Required

LANEMARK INTERNATIONAL TX BURNER MANUAL DESPATCH/PACKING LIST

Despatch/Packing List Page 5

If this manual was sent out with an actual burner a copy of the Despatch / Packing list will be included after thispage.

This will give all the components and sub-assemblies sent out. Some items may have quantity zero against apart number as these were included for reference only as the customer may be supplying these parts to adesign supplied by Lanemark.

Many part numbers are also accompanied by their corresponding drawing number e.g. gas trains and normallythese drawings will be included in this manual.

LANEMARK INTERNATIONAL TX BURNER MANUAL CERTIFICATES

Certificates Page 6

If this manual was sent out with an actual burner a copy of the :- • Declaration of Conformity to Order • Declaration Of Incorporation ). • Test Certificates. • Calibration Certificates. • Certificates for equipment supplied by Lanemark International Ltd but not manufactured by Lanemark. will be included after this page if specifically requested by the Customer’s order.

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 1 GENERAL DESIGN

Section 1 Page 1

SECTION 1 GENERAL DESIGN


Section 1 Page 2

BRIEF BURNER SPECIFICATION

Lanemark International Ltd TX gas fired immersiontube heaters are designed for high efficiency fluidheating in industrial tanks, baths, vats, etc. Eachsystem comprises of an induced draught gas burnerfiring into a small bore tube heat exchanger immersedin the fluid. The smallest model, the TX15 fires intopipe size nominally 1 ½” ( 40 mm ) and the largestmodel, the TX60 into pipe size 6” ( 150 mm ).

The heat exchangers are individually computerdesigned and manufactured by Lanemark ( or othersto our design ), to ensure maximum efficiency andprocess flexibility and so achieving the minimumprocess operating costs. Minimum efficiencies of :-

80.0 % ( gross calorific value )90.0 % ( net calorific value )

are achievable. The heat exchanger passes throughthe wall of the tank and is sealed by a flange andgasket. Due to the low initial heat release at the tankconnection fibreglass or rubber lined tanks may beused. The burner body mounts onto one end of theheat exchanger and a flue damper to the other. Theflue damper is then connected on site to the inlet ofthe centrifugal flue fan which may serve one orseveral TX burners.

The burners are available for both Natural Gas andL.P.G Propane Gas and fuel only is controlled toeffect an accurate turndown.

The control panel contains the burner programmerunit, on/off switch and all controls necessary includinga 3 way air valve which allows the burner to beapplied to installations where the exhaust fan runscontinuously.

The burners are supplied with 230V or 110V controlsand fan motors are generally 3 phase 380-415 V. Thefan motor can be energised from the burner controlbox via an isolator, contactor and motor protectionprovided by others. Alternatively the fan can runcontinuously, independently of the burner controlpanel, using the appropriate interlocks especially ifone fan serves several burners.

TX control panels can be supplied to serve a single ormultiple burners as required.

SHIPPING CONTENTS

The burner is shipped in a single heavy dutycardboard box with an infill of polyurethane foam.Fans are transported on a wooden pallet and shrinkwrapped over or similar.

CONSTRUCTION STANDARDS

The burners are generally constructed in accordancewith :-

EN 746 Part 1: Common Safety Requirements ForIndustrial Thermoprocessing Equipment

EN 746 Part 2: Safety Requirements For CombustionAnd Fuel Handling Systems Of IndustrialThermoprocessing Equipment

EN 676 Automatic Forced Draught Burners ForGaseous Fuels

As these burners are intended to be incorporated intoanother machine or system they are supplied with aCertificate of Incorporation as required by theMachinery Directive 89/392/E EC and are not CEmarked as burners for hot water or steam boilers.

GENERAL DESIGN CONSIDERATIONS

The burner must be installed in accordance with thefollowing regulations :-

I.E.E Regulations ( BS7671 )Local Gas Service Area RecommendationsBS5440 Part 1 Specification For Installation Of FluesBS5440 Part 2 Specification For Installation OfVentilation For Gas AppliancesBS6644 Installation Of Gas Fired Boilers Between60kW And 2MWBritish Gas IM/30 Code Of Practice For Gas FiredProcess PlantBritish Gas IM/11 Flues For Commercial And IndustrialGas Fired Boilers And Air HeatersBritish Gas IM12 Use Of Gas In High TemperaturePlantBritish Gas IM/18 Use Of Gas In Low TemperaturePlantLPGA COP9 LPG Air PlantLPGA COP17 Purging LPG Vessels And SystemsIGE/UP/1 Soundness Testing And Purging OfIndustrial And Commercial Gas InstallationsIGE/UP/4 Commissioning Of Gas Fired Plant OnIndustrial And Commercial PremisesIGE/UP/2 Gas Installation Pipe work, Boosters AndCompressors On Industrial And Commercial Premises

INSTALLATION

It is UK Law that these burners are installed,commissioned and maintained by competent personse.g. C.O.R.G.I registered installers with ACOPSCertificates only. For use in other countries localregulations must be complied with.


Section 1 Page 3

Fig 1 TX GENERAL DIMENSIONS

DIMENSIONS ( in mm, except where stated ).MODELTYPE:

A B C D E F G H

TX 15TX20

220 150 40 305 75 ½” BSP 160 12

TX25ETX30

295 225 50 450 75 1” BSP 210 25

TX40 295 300 50 500 75 1 ½”BSP

230 25

TX60 405 320 120 625 75 2” BSP 305 35


Section 1 Page 4

Fig 2 TX EXPLODED VIEW


Section 1 Page 5

Fig 3 GENERAL ARRANGEMENT OF INSTALLATION

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 1 DESIGN GENERAL

Section 1 Page 6

HEAT EXCHANGER DESIGN

The burners are suitable for direct firing into tubesranging from 1 ½” ( 40 mm ) up to 6” ( 150 mm ) heatexchangers depending on the design.

Section 2 of this manual contains details of the heatexchanger design and application.

FAN EXHAUST DAMPER

The air flow through the burner which is fundamentalto the safe and efficient combustion of the fuel gas iscontrolled by a flue damper which is supplied byLanemark.

This damper is shown in Fig 4 and it should beinstalled as shown with the 6 mm fitting for the air flowpressure sensing pipe facing upwards so this 6 mmpipe does not fill with condensation.

The damper is screwed onto the parallel thread on theexit end of the heat exchanger and fixed by a backnut.

Sufficient clearance should be allowed around thisdamper for Service Engineers to gain access to thebutterfly adjusting bolt head and also to the flue gastest sampling point.

EXHAUST PIPE FROM DAMPER TO FAN

This flue connection ( see Fig 3 ) should be made infabricated steel heating pipe typically in a size onepipe size larger than the flue damper size.

The flue damper should be connected to the fan inletin solid steel pipe which is normally welded.

Sufficient break flanges should be included so that itis possible to remove the fan. For multiple burnerssharing a common fan, individual dampers will beconnected into a common manifold.

The size of the final pipe connection and the fan inletflange must be the same size. The final piece of pipemust be a straight run of minimum length 500 mm.Lanemark would be pleased to advise on the designof the manifold.

If, however it is decided to use a clip together fluesystem it must be gas tight against 25 mbar suction atup to 300 °C for the life of the system when subject tovibration, condensation etc. Domestic boiler spiralwound flexible flue liner pipe is an unsuitable materialfor this flue run.

FLUE FROM SEVERAL DAMPERS TO A COMMON EXHAUST FAN

This will again be run in fabricated steel pipe asprevious. The size will be that which maintains thecollective cross sectional area of all the branches thattee into it. Tees should be swept in and not at rightangles. As a rule of thumb the hot flue gas velocityshould not exceed 20 m/s.

EXHAUST FLUE FAN

This exhaust flue fan will generally be supplied byLanemark and may serve a single or multiple burners.

The fan is generally supplied as an R90 type using theFan Industries standard system for describing thegeometry of the fan outlet relative to the inlet. Otherconfigurations e.g. L90 can be supplied to specialorder. The fan and its impeller are mild steel but othermaterials e.g. stainless steel can be supplied tospecial order. The drawing in Fig 5 and its table ofdimensions shows a typical fan with motor electricaldata and approximate weights.

The standard fan must be installed with its pedestal onthe ground or a suitable support. Only special sidemounting versions can be installed on their side.

FLUE SYSTEMS

The flue from the exhaust fan will typically be a twinwall insulated stainless steel system suitable for theflue gas temperature of up to 300 °C. Domestic boilertype spiral wound flexible flue liner pipe is unlikely tobe suitable material for this application. Lanemarkalways recommend that the flue terminate outside thebuilding and sufficiently high above the roof to be in adowndraught free zone. If this is not possible seeSection 14 “ Health and Safety “ on this aspect. Theflue pipe must never be smaller than the fan outletsocket which is non load bearing and the flue shouldbe rigidly connected and the joint sealed.

For some installations Local and National GovernmentDepartments should be contacted for approval todischarge flue gas and this is the responsibility of theinstaller.

If the flue is to be finished with a flue cap it should bea simple Chinaman's cap or similar that offers minimalresistance to the escape of the high velocity flue gas.A free length of 150 to 200mm to the underside of thecap is typical.

For all flue designs ( especially designs where the hotflue gas passes to a second heat exchanger or a dryoff stage) Lanemark International would be pleased tocomment on the suitability of the design.


Section 1 Page 7

TEMPERATURE CONTROLLERS

Generally the burner is a high to low to off burner.The burner should be commissioned such that lowfire is not sufficient to maintain the tanktemperature. Then the main high flame will bebrought in intermittently to maintain the set point.

It is anticipated that a digital electronic temperaturecontroller will be supplied either by Lanemark as anoptional accessory or by the installer.

This controller should have a set point and anadditional alarm stage. The set point contacts willswitch the burner down from high fire ( full output )to low fire. The alarm stage will then switch theburner from low fire to all off should the tanktemperature continue to creep upwards. It will thenbring it back on once the temperature has fallenbelow the setpoint again.

This controller can be a simple set point controllerwith fixed differentials for high/low/off burners.On/off gas valves should not be switched more than4 times a minute.

Where the thermal response of the system isrelatively slow due to the large quantity of liquidbeing heated a simple dual mechanical thermostatcould be used.

Alternatively modulating burners may have beenspecified and a full 3 term P.I.D controller can beused as required to suit the characteristics of theapplication. A control signal of 0(4) – 20 mAmp,0(2) – 10 V dc or 3 wire direct valve positioning canbe specified.

It is recommended that consideration be given tofitting a second totally independent temperaturecontroller. This may be necessary if the liquid beingheated is cooking oil or similar. This will act as aHigh Temperature Trip Thermostat ( PolicemanThermostat ). Once its set point has been exceededthe burner is held off until manual interventionoccurs to reset it.

See the wiring diagram for details of thetemperature controller connection. The TechnicalDepartment of Lanemark would be pleased toreceive electrical and control installation drawingsfor comment.

LIQUID LEVEL PROTECTION

In addition to the temperature control a suitable floatswitch, ultrasonic liquid detector or similar should be

used to protect the burner from firing into a heatexchanger that is not fully covered by the liquid.

This liquid level detector could be automatic reset ifthe tank has an automatic filling system and shouldbe connected into the burners control circuit in asimilar way to the temperature controller.

VENTILATION SYSTEMS

The burner should only be installed in a productionarea with sufficient natural or mechanical ventilationto ensure that there is adequate fresh air forcomplete combustion and adequate extract tomaintain an acceptable working environment.

The burner should not be installed in an area wherethere is a high level of powered mechanical extractbut only natural ventilation inlet air. With such acombination the mechanical extract system maystarve the burner of combustion air.

For suggested values for natural and mechanicalventilation see BS6644.

Where the air supply quality cannot be ensuredconsideration should be given to ducting fresh air infrom outside.

PROTECTION OF BURNER SYSTEMS

The burner control panel and the gas train aremanufactured to IP54 with regard to their protectionagainst water and dust. This standard is sufficientfor most commercial applications.

If the burner area is to be washed down with a hosepipe, or if the burner is to be used in an area withexcessive condensation, or subject to tanksoverflowing or similar, then the gas train andcontrols must be protected from the ingress of anywater and liquid.

If the air is very contaminated with chemicals ordust then the burner should have its air forcombustion vented in from a source of fresh cleanair.

Lanemark can supply equipment to higher IPstandards, equipment manufactured from stainlesssteel for food preparation areas and withconnections for fresh air ducts.


Section 1 Page 8

ELECTRICAL SUPPLY The burner is available with :- 230V 1 Phase 50 Hz or 110V 1 Phase 50 Hz controls & gas trains as given on the Burner Data Plate (a duplicate is included in the front of this manual ). The single phase 230V or 110V control panel supply should be made into the control panel through a M20 cable gland from a suitable isolator and fused supply. The cable should be run in cable of sizes suitable for the panel load of 250 VA . All cable should be suitable for a service temperature of 60 degrees centigrade. THIS BURNER MUST BE EARTHED The exhaust fan(s) will generally be supplied by Lanemark International Ltd. The fan motor power and the full load current will be contained on the Data Plate a copy of which is in the front of this manual if this manual was sent out with a burner. The fan should have an independent isolator, motor protection device, contactor with an auxiliary contact provided by others. Alternatively Lanemark would be pleased to supply this as an optional extra. The fan can run continuously from the main plant control panel. The burner must only run when the fan is running and stop immediately if the fan motor overload trips. An auxiliary contact on the motor overload should be interlocked to the burners own control panel. See the wiring diagram details. Alternatively the fans motor contactor can be energised from the burners own control panel as shown in the wiring diagram. All electrical installations should be in accordance with I.E.E Regulations ( BS7671 ). Output signals are available from the burners control panel, at 230V AC or 110V AC as appropriate for burner ON HIGH / ON LOW / AT LOCKOUT. Time switches and ON/OFF switches should be connected as shown in the wiring diagram and temperature controllers as discussed later. Main motor control panels must never backfeed electrically into the Lanemark control panel. If several burners are installed on a common system they must not backfeed each other electrically . Isolating or 110V transformers must be end and not centre tapped. The burner control box may have depending on the model over/under voltage protection and will not run if the supply voltage is incorrect.

Remote reset of control box lockout is possible by briefly applying a 110V or 240V input reset signal or pulling the reset terminal down to neutral briefly as appropriate for the box type. Use the burner’s own Data Plate to identify the correct wiring diagram and check this for the applicable method of reset. GAS SUPPLY GENERAL Before the burner is connected to a new or existing gas supply the Local Gas Supply Service Provider must be consulted to ensure that the gas meter and supply are of adequate size for the load required. The burner gas train includes an isolating ball valve and union to allow the burner to be isolated and removed for servicing and a coarse filter. The pipe work final connections should be made such that it is possible to isolate the gas supply and remove the burner for servicing without removing any gas pipe work. Consideration may be given to making the final connection in an armoured flexible gas hose that complies with current standards. The gas supply pipe work should be designed and installed in accordance with the standards listed previously. GAS SUPPLY: NATURAL GAS A stable gas supply pressure supply of:- 20 mBar ( 8 in.wg ) minimum inlet pressure 35 mBar ( 14 in.wg ) maximum inlet pressure is required with the burner(s) running and if the supply is a medium pressure supply, or above the maximum required, an additional gas regulator should be installed. GAS SUPPLY: PROPANE GAS The burner should be connected to a Propane supply of sufficient capacity so that at full out put the draw off rate of the storage system and its regulators is not exceeded. This burner should not be used on Propane/Butane or Propane/Air mixtures. A stable supply pressure of:- 35 mBar ( 14 in.wg ) minimum inlet pressure 50 mBar ( 20 in.wg ) maximum inlet pressure is required with the burner(s) running and if the supply is above the maximum required an additional gas regulator should be installed. Low and high pressure cut offs with vents must be fitted and care taken in the design to prevent governor lockup or nuisance trip of these cut offs.


Section 1 Page 9

Fig 4 FLUE EXHAUST DAMPER

IMPORTANT: The damper assembly should be installed as shown with the 6 mm air sensing connection pointing upwards ( to prevent condensation blocking it ) and with sufficient clearance all around to allow Service Engineers access to set the damper quadrant and to use the combustion test point.


Section 1 Page 10

Fig 5 GENERAL ARRANGEMENT OF EXHAUST FAN


Section 1 Page 11

Fig 5 TABLE OF DIMENSIONS FOR FAN


Section 1 Page 12

Fig 5 TABLE OF DIMENSIONS FOR SILENCERS

SIDE VIEW

END VIEW

MATERIAL:-OUTER CASE 16g (1.6mm) FULLY WELDED INNER FACES 22g (0.7mm) GALVANISED PERFORATED SHEET

FINISH:-HEAT RESISTANT BLACK PAINT

DA

G

C

B

F

AE

FAN TYPE PART NO. A B C D E F G12/030DF 80082 50 300 600 130 127 300 120012/125DF 80083 75 300 600 130 127 300 120012/200DF 80084 102 300 600 155 150 300 120024/150DF 80086 75 300 600 155 150 300 120024/300DF 80087 102 300 900 210 205 300 150024/400DF 80089 102 300 900 210 205 300 150024/600DF 80090 150 300 900 260 255 450 150030/150DF 80091 75 300 600 155 150 300 120030/300DF 80092 102 300 900 210 205 300 150030/400DF 80093 125 300 900 260 255 450 150030/600DF 80094 125 300 900 260 255 450 1500

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 2 HEAT EXCHANGER DESIGN

Section 2 Page 1

SECTION 2 HEAT EXCHANGER DESIGN


Section 2 Page 2

HEAT EXCHANGER DESIGN

The burners are suitable for direct firing into tubesranging from 1 ½” ( 40 mm ) up to 6” ( 150 mm )depending on the application.

Figure 1 shows a typical flange mounted and platemounted heat exchanger tube. Figure 2 and Figure3 show the detail of the flange mounting and thesupport of the heat exchanger within the tank. Platemounted heat exchangers are similar.

Normally the heat exchangers are manufactured byothers to principal dimensions supplied byLanemark International Ltd or our official agents. Ifthe heat exchanger is supplied by Lanemark thereare some general considerations that should betaken into account.

The heat exchangers are suitable for direct firing bya Lanemark TX gas burner only with :-

Internal pressure 100 mbar negative max’Internal wall temperature 300 °C maximumExternal pressure 0.5 bar max’ open tankExternal temperature 150 °C maximumInternal Test Pressure 2 bar for 30 minutes.

The heat exchangers tubes supplied by Lanemarkare manufactured to our own internal standards andsuitable for the above application but are notdesigned and manufactured to a specific heatexchanger or pressurised piping system designcode. Full constructional details are available onrequest.

If the heat exchanger is to be used as an integralpart of a coded heat exchanger or piping systemthen Lanemark should be contacted at the designstage to ensure compliance with that code.

The heat exchanger material will generally beBS1387 medium grade steel heating pipe but foraggressive applications other materials such asstainless steel Grade 316L Schedule 10 or othersuitable materials may be used.

The length of the first leg of a multipass heatexchanger must be at least 10 to 15 pipe diametersand normally the first bend must be a long radiusbend as determined by the Lanemark TX CalcDesign Software.

The initial heat release into the heat exchanger isquite low and fibreglass or rubber lined tanks maybe used.

The heat exchanger is generally situated as close tothe tank bottom as possible and the top of the toptube must be covered by at least 100 mm of liquid.

The heat exchanger must not come into contactwith sludge and sufficient space must be allowedbeneath the heat exchanger to allow for any sludgeto accumulate.

The heat exchanger must be protected fromaccidental damage when the work pieces areimmersed into the tank. A suitable guard should beincluded if there is any possibility of such damageoccurring.

The heat exchanger must be supported if the lengthis sufficient to warrant this. The heat exchanger hasa tendency to float upwards when filled with hot fluegas. A suitable support arrangement is shown in Fig3 that allows for some but not excessive movementof the heat exchanger.

The heat exchanger must be protected fromrunning when the tank liquid level is insufficient tocover it and a low liquid level protection deviceshould be fitted.

The liquid temperature will have to be controlledand a thermostat or digital temperature controller isnormally fitted into the tank inside a pocket so thatthis device can be replaced without draining thetank.

A single butyl rubber gasket is normally used to sealeach flange to the tank and is used on the inside ofthe tank. For most commercial applications butylrubber gaskets are satisfactory but the suitability ofthis should be checked at the design stage and ifnecessary PTFE or other gasket materials can besupplied.

If the tank is manufactured from stainless steel asecond gasket is used on the outside face toprevent the mild steel slip on external flangecausing a rust stain on the stainless steel. This isgenerally a butyl rubber gasket.

HEAT EXCHANGER DESIGN DRAWINGS

If this manual was supplied with the burner on aproject where a heat exchanger was designed byLanemark, a copy of the heat exchanger drawingwill be included in this section of the manualshowing the principal dimensions.


Section 2 Page 3

Fig 1 FLANGE AND PLATE MOUNTED HEAT EXCHANGERS

NOTE:-INSULATION TO BE CUT AWAY IN VICINITY OF FLANGES.

FLANGED CONNECTION TO TANK

PLATE CONNECTION TO TANK


Section 2 Page 4

Fig 2 SPIGOT MOUNTED AND DOWNFIRING HEAT EXCHANGERS

TYPICAL TANKFITTING OF SPIGOT

TYP

TYP100150

NOTE:-INSULATION TO BE CUT AWAY IN VICINITY OF FLANGES.

OPTIONAL LANEMARKSUPPLY OF SPIGOT

SPIGOT CONNECTION TO TANK

DOWNFIRING CONNECTION TO TANK


Section 2 Page 5

Fig 3 HEAT EXCHANGER FLANGE MOUNTING DETAIL

Fig 4 HEAT EXCHANGER SUPPORT

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 3 CONTROL PANEL DESIGN

Section 3 Page 1

SECTION 3 CONTROL PANEL DESIGN


Section 3 Page 2

CONTROL PANEL

The control panel supplied by Lanemark isgenerally designed to suit each individualcustomers requirements with regard to :-

Voltage 110V / 230VBurner programmer ( Satronic / Landis /Honeywell )Temperature controllerFan motor controlInterface to gas trainGas train modulation control

The burner can be supplied with :-

1. Standard polycarbonate control box containingburner programmer and all parts required tosupervise the burner only.

2. Full steel control cabinet including motorcontrol, time switches, temperature control etc.

3. Local junction box containing only those partsthat must be situated immediately adjacent tothe burner ( burner programmer not included ).

4. No controls by Lanemark ( supplied by others ).

Generally Item 1 the standard polycarbonate controlbox is supplied and this is interfaced to thecustomers own main control panel ( whereapplicable ).

Figure 1 shows the general layout of this panelwhich will contain :-

On / Off / Lockout Reset switchControl fuseDin Rail terminals to suitBurner control programmerIgnition transformer3 way air valveAir pressure switch

And if the application requires it :-

Temperature controllerModulating gas valve transformer and interfaceTime clock

INTERFACE WIRING DIAGRAM

Lanemark produce an Interface Wiring Diagram foreach burner supplied. If this manual wasdespatched with a burner this manual will containthe correct Interface drawing in this section of themanual.

The important interface connections are :-

1 Main 1 phase supply ( 110V or 230V asspecified ) rated for a 250VA load.

2a Remote reset of burner lockout by a brief 110V / 230V input. The cable must be protected from

induced voltages ( see the specific drawing ).2b Alternatively the box’s reset terminal may require pulling down to neutral to effect the reset ( see the specific wiring drawing ).3. Fan auxiliary contact – a pair connecting to an

auxiliary contact on the fan motor’s contactorwhich will stop the burner immediately if the fanmotor overload trips in operation.

4. Fan motor call signal to fan contactor’s coil.5. Remote burner ON lamp.6. Temperature control Set Point “ SP “ ( high to

low fire switch ).7. Temperature control alarm point “ AL “ ( low

fire to off switch and time switches etc. ).

If modulating gas valves are being used additionalconnections will be required to drive the modulatingmotor by a control signal and these should beconnected with reference to the wiring diagram.Particular attention must be paid with 0-10 V dc or4-20 mA signals in tying the neutrals ( or grounds )together to complete the circuit.

Where several burners are connected back to amain control panel or share a single fan it isIMPORTANT that one burner’s electrical interfaceconnections do not backfeed to another burner.

Three more electrical connections are required :-

1 Connection to ignition probe on burner body.2 Connection to flame sensing probe (or U.V

cell).3 Multicore connection to the gas train.

Lanemark premake these in 3 metre long PVCflexible conduit but disconnect them for transport.The terminals are labelled or numbered forreconnection on site.

Two off 6mm steel or copper pipe connections aremade to the control panel’s air pressure switch fromthe burner body and the flue damper.

PANEL INTERNAL WIRING DIAGRAM

If this manual was despatched with a burner thismanual will contain the correct Internal WiringDiagram in this section of the manual.

The correct drawing number is given on eachburner’s Data Plate and a duplicate Data Plate isincluded in the front of this manual.


Section 3 Page 3

Figure 1 CONTROL PANEL

Control Panel Layout ( Size W=372 H=282 D=180 mm )

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 4 TEMPERATURE CONTROL DESIGN

Section 4 Page 1

SECTION 4 TEMPERATURE CONTROL DESIGN


Section 4 Page 2

TEMPERATURE CONTROL

The burner can be designed to operate :-

1. On / off2. Or High / low3. Or Modulating gas at fixed air4. Or Modulating air and gas

to suit the application requirements.

Usually the burners are supplied as high/low/off ( oron/off which is just high/low with a link added in theLanemark control panel ).

The burner is normally commissioned with the lowfire such that it is not sufficient to hold the processtemperature at the Set Point “ SP “ and thetemperature controller brings the burner back in athigh fire to top up the temperature. The low fireshould not exceed 30% of high fire to comply withthe standards to which the burner is built. If theprocess temperature exceeds the AlarmTemperature “ AL “ then the alarm stage of thetemperature controller switches the burner fromlow fire to off.

A second independent temperature controller mayhave been specified at the design stage to act asPoliceman or High Limit Thermostat. Should theprocess temperature exceed the Set Point and alsothe normal Alarm Point ( possibly because themain temperature controller has failed ), then thissecond thermostat will switch the burner off andnot allow automatic restart.

The temperature controllers for on/off or high/lowcontrol are typically simple mechanical thermostatsor digital electronic controllers that areprogrammed for on/off control and the P.I.D andAutotune facility are disabled. An on/off gas valveshould not be switched more than 4 times aminute.

For processes that require accurate temperaturecontrol a modulating gas valve may be fitted andthis will be driven by a 0(2 ) - 10 V dc , 0(4) - 20mAmp or 3 wire direct valve positioning signals.

Lanemark normally use 24V AC modulating motorson gas valves and the 24V AC power supply issupplied by Lanemark if a control panel is supplied.

For 3 wire valve positioning motors ( a simple 24V,110V or 230V feed is used to open and then toclose the modulating motor ) the electronictemperature controller must have slave relaysplaced between itself and the modulating motor.

This is to protect its internal contacts which aregenerally rated at a fraction of an Amp and not ableto carry the associated in-rush current.

WIRING OF TEMPERATURE CONTROLLERS

If Lanemark supplied an electronic digitaltemperature controller and built it into the controlpanel the wiring diagrams contained in this manualwill show this controller.

Generally the only additional field wiring will be toconnect the temperature sensor back to the controlpanel. This must be done in suitable cable andscreened.

For simple mechanical thermostats if these weresupplied by Lanemark these will require field wiringback to the control panel and interconnecting asshown on the Interface Wiring Diagram.

SETTING / PROGRAMMING CONTROLS

If Lanemark supplied temperature controls with aburner a Data Sheet will be contained in thissection of the manual detailing how to programmeand adjust them.

TEMPERATURE SENSORS

For electronic temperature controllers Lanemarkgenerally supply Pt100 ( platinum resistance )sensors to suit the controller with an industrial stylehousing.

For mechanical thermostats Lanemark generallysupply single ( on/off control ) or dual ( high/lowcontrol ) thermostats to suit the application. Thesehave a plastic housing and the adjustment dials areunderneath a cover and cannot be accidentallyadjusted.

A stainless steel pocket approximately 300 mmlong is also supplied with both types of sensor sothat the sensor can be replaced without drainingthe tank.

The tank will require a ½” BSP boss adding to thewall in a position where the sensor will detect arepresentative temperature. This position must besuch that the sensor will not be damaged whenbaskets of work are dropped into or passedthrough the tank.

A data sheet will be included in this section of themanual if such a sensor was supplied.


Section 4 Eagle 2048D Temperature Controller P1

EAGLE 2048D-H-R TEMPERATURE CONTROLLER Lanemark Part No. 12004 (110V & 230V) The Eagle 2048D is a general purpose digital temperature controller for use with a PT100 (Platinum Resistance) thermometer sensor which is normally supplied by Lanemark with the controller, if specified. The controller is normally built into control panels supplied by Lanemark but may be supplied as a loose item. If the controller was built into a panel by Lanemark the wiring diagram will be contained in this manual or if it was supplied as a loose item the connections are shown below. The full model number is Eagle 2048D-H-R and the type is 2048D1010C (PT100). If any problems are encountered this specification number and the instruments own serial number can be found on a label on the side of the instrument. The controller cannot be used with any other temperature sensor e.g. a K-Type thermocouple without having internal links on its printed circuit board re-set. The controller is suitable for a power supply voltage between 100 and 240V single phase AC. The Eagle is 1/16 DIN and 48mm x 48mm. The controller has the facility for autotuning and P.I.D control but for High/Low or On/Off burners these features will not be used. The controller has two internal sets of contacts that are used to switch the burner from High to Low fire (called the Set Point ‘SP’) and from Low fire to Off (called the Alarm Temperature ‘SL’). These contacts are rated at 3 Amp resistive and a slave relay rated at 5 or 10 Amps may be used on both stages to protect the contacts. The burner is normally commissioned with the Low fire such that it is not sufficient to hold the process temperature at the Set Point ‘SP’ and the temperature controller brings the burner back in at high fire to top up the temperature. If the process temperature exceeds the Alarm Temperature ‘SL’ then the alarm stage of the temperature controller switches the burner from Low to Off. For On/Off burners the ‘SP’ & ‘SL’ settings are the same, thus the burner goes between High Fire and Off. EAGLE 2048D-H-R CONNECTIONS

SETPOINTOUTPUT

" SP"

PT100SENSOR

ALARMOUTPUT

" SL"

N

LPOWERSUPPLY

100 - 240V AC

54

3

21 11

10

9

876

SUPPRESSORMOV to 275V

6

12

8

7N/O

ALARMRELAY

N/C

N/O 9

11

106A

TEMPERATURECONTROLLER

34

5

6B

HIGH/LOWCIRCUIT

+ -

PT100SENSOR

SUPPLY LN

1A



EAGLE 2048D PROGRAMMING THE SET POINT ‘SP’ AND ALARM ‘SL’ The Set Point ‘SP’ is the temperature at which the tank of liquid should be maintained, generally by switching the burner from high to low fire. The Alarm Trip Point ‘SL’ is the temperature at which the tank of liquid has exceeded the normal set point temperature, typically by 3°C. The burner is switched from low to off as the alarm temperature is reached. When this happens the red LED (light emitting diode lamp) ‘I’ will go out. Once the temperature falls below the Alarm Temperature by 2°C the LED will come back on and the burner will restart.

Lights On:-

°C/°F - Temperature Reading in °F

M & I - High Fire

I Only - Low Fire

II - Not Used

Return to Previous Parameter

Step DOWNStep UP

Programme Entry & Next Parameter

ACTUAL PLANT TEMPERATURE

"PV"

SETPOINTTEMPERATURE

"SP"

Method of Entering Set Point Parameters (with standard Lanemark default settings – see over)

Press ‘F’ and ‘_SP’ appears - Using the UP and DOWN keys the Set Point can be altered.

Press ‘F’ again ‘_SL’ appears - Using the UP and DOWN keys the Alarm Trip Point can be altered.

Press ‘F’ - The new SET POINT is now entered.

Press ‘F’ & ‘R’ together - The screen reverts to normal display. Wait 12s for automatic reset.

Note: Set Point and Alarm Trip Point values are determined by the temperature sensor input and are pre-set

by Lanemark to:- Fluid Temperature Flue Gas Temperature Flue Gas Temperature (Dual Alarm) (Single Alarm) _SP 40°C 250°C 300°C _SL 60°C 300°C 300°C These should be adjusted for site requirements, however are limited from -199°C to 500°C.



EAGLE 2048D PROGRAMMING THE OPERATOR PARAMETERS Press and hold ‘F’ until ’_OP’ appears, release the ‘F’ key and ‘_Pb’ appears. In the top window you will see the name of the parameter you are setting and in the bottom window the current value. Using the UP and DOWN keys the value can be altered. When complete press ‘F’ to move onto the next parameter to be set.

PARAMETER

CODE DESCRIPTION OPTION CODES DESCRIPTION LANEMARK

PRESET

_Pb PROPORTIONAL BAND 000 to 999 For On / Off & High / Low Burners the Proportional Band is not required 000

_H¯ UPPER LIMIT HYSTERESIS 000 to 100 Adjustable Band on High side of Set Point High Fire to Low Fire at SP plus H¯ 001

_H_ LOWER LIMIT HYSTERESIS 000 to 100 Adjustable Band on Low side of Set Point Low Fire to High Fire at SP minus H_ 001

_Ct CYCLE TIME 001 to 100 Check time in s - Averages temperature readings to prolong life of components 020

_CF DEGREES C or F C of F C - Temperature in Degrees Centigrade F - Temperature in Degrees Fahrenheit C

_HC HEATING or COOLING H or C H - Heating Control C - Cooling Control H

000 OLE - Out of Limit Energise 001 HLE - High Limit Energise 002 LLE - Low Limit Energise 003 SSPE - Independent 2nd Set Point Energise 004 OLDE- Out of Limit De-Energise 005 HLDE - High Limit De-Energise 006 LLDE - Low Limit De-Energise 007 SSPDE - Independent 2nd Set Point De-Energise

_LI ALARM OPTIONS

008 Alarm Off

007

_LO MAIN SET POINT MINIMUM -199 to 999 Lower Limit on Temperature Reading. Restricts the temperature range of the ‘SP’. 000

_Hi MAIN SET POINT MAXIMUM -199 to 999 Upper Limit on Temperature Reading. Restricts the temperature range of the ‘SP’. 100

Press ‘F’ & ‘R’ together or wait 12s for automatic reset. The screen reverts to normal display. Notes: See Page 5 for a definition of the Alarm Options ‘LI’. Minimum and Maximum Set Points (LO & Hi) are pre-set by Lanemark to 0 – 100°C. This will be suitable for most fluids, but Hi should be further restricted for temperature critical fluids. The Upper and Lower Limit Hysteresis values (_H¯ & _H_) are based on a percentage of the

difference between the Minimum and Maximum Set Points (LO & Hi), therefore by having the standard Lanemark settings these values equate to 1°C.

If the Controller is to be used for Flue Gas Hi will be pre-set to 300°C. This may be increased if the design temperature is near to this figure (see TxCalc). For alarm only outputs on Flue Gas LI will be pre-set to 005, with SL & SP set to 300°C. The Security Code hL will be pre-set to 003, disabling access without entering the code.



EAGLE 2048D PROGRAMMING THE CONFIGURATION PARAMETERS Press and hold ‘F’ until ’_Cn’ appears, release the ‘F’ key and ‘_OF’ appears. In the top window you will see the name of the parameter you are setting and in the bottom window the current value. Using the UP and DOWN keys the value can be altered. When complete press ‘F’ to move onto the next parameter to be set.

PARAMETER

CODE DESCRIPTION OPTIONCODES DESCRIPTION LANEMARK

PRESET

_OF OFFSET -100 to 100

Compensation Value for any error in the process variable value. DO NOT ADJUST. 000

000 No Security 001 Configuration Parameters locked. 002 Configuration & Operator Parameters locked.

_hL SECURITY CODE

003 ‘SP’, ‘SL’ & Config. & Operator Parameters locked.

002

000 PT100 (RTD) Range: -199°C to 500°C 001 PT100 (RTD) Range: -19.9°C to 99.9°C 002 J' Type Thermocouple Range: 0°C to 900°C 003 K' Type Thermocouple Range: 0°C to 999°C

_In INPUT TYPE

004 mA / mV Range -199 to 999

000

_dL LINEAR INPUT LOW -199 to 999

For On / Off & High / Low Burners the Linear Input is not required. Used for PID control only. Setting irrelevant. 000

_dH LINEAR INPUT HIGH -199 to 999

For On / Off & High / Low Burners the Linear Input is not required. Used for PID control only. Setting irrelevant. 000

000 No decimal points 001 1 decimal point _dP DECIMAL POINTS 002 2 decimal points

000

_AS APPROACH CONTROL 000 to 100

For On / Off & High / Low Burners Approach Control is not required. Used to reduce Overshoot on PID. Setting

irrelevant. 000

Press ‘F’ & ‘R’ together or wait 12s for automatic reset. The screen reverts to normal display. Notes: The security code hL is pre-set to 002 for most applications, 003 for Flue Gas (Single Alarm). In order to modify any settings it is necessary to scroll through the display, as above,

alter hL to 000 and reset to normal display. All values can now be re-programmed. This security code should be reset to prevent accidental alteration of the parameters.



DEFINITION OF ALARM OPTIONS

NO

TES

SL' &

'SP'

are

link

ed.

Any

cha

nge

in 'S

P' w

ill c

ause

the

alar

m tr

ip p

oint

'S

L' to

mov

e th

e sa

me

num

ber o

f deg

rees

.

The

alar

m tr

ip p

oint

'SL'

is to

tally

inde

pend

ent o

f 'SP

'.

Any

cha

nge

in 'S

P' w

ill n

ot a

ffect

'SL'

.

SL' &

'SP'

are

link

ed.

Any

cha

nge

in 'S

P' w

ill c

ause

the

alar

m tr

ip p

oint

'S

L' to

mov

e th

e sa

me

num

ber o

f deg

rees

.

The

alar

m tr

ip p

oint

'SL'

is to

tally

inde

pend

ent o

f 'SP

'.

Any

cha

nge

in 'S

P' w

ill n

ot a

ffect

'SL'

.

SL' O

ff

FUN

CTI

ON

Out

of L

imit

Ener

gise

R

elay

ene

rgis

es e

ither

sid

e of

'SP'

, whi

ch d

epen

ds o

n al

arm

set

ting

valu

e 'S

L'.

Hig

h Li

mit

Ener

gise

R

elay

ene

rgis

es a

bove

'SP'

, whi

ch d

epen

ds o

n al

arm

set

ting

valu

e 'S

L'.

Low

Lim

it En

ergi

se

Rel

ay e

nerg

ises

bel

ow 'S

P', w

hich

dep

ends

on

alar

m s

ettin

g va

lue

'SL'

.

Inde

pend

ent S

econ

d Se

t Poi

nt E

nerg

ise

The

Ala

rm R

elay

is to

tally

inde

pend

ent o

f 'SP

'. Th

e al

arm

is d

e-en

ergi

sed

belo

w 'S

P'

until

'SL'

is re

ache

d, th

e re

lay

then

ene

rgis

es.

Out

of L

imit

De-

Ener

gise

R

elay

de-

ener

gise

s ei

ther

sid

e of

'SP'

, whi

ch d

epen

ds o

n al

arm

set

ting

valu

e 'S

L'.

Hig

h Li

mit

De-

Ener

gise

R

elay

de-

ener

gise

s ab

ove

'SP'

, whi

ch d

epen

ds o

n al

arm

set

ting

valu

e 'S

L'.

Low

Lim

it D

e-En

ergi

se

Rel

ay d

e-en

ergi

ses

belo

w 'S

P', w

hich

dep

ends

on

alar

m s

ettin

g va

lue

'SL'

.

Ind

epen

dent

Sec

ond

Set P

oint

De-

Ener

gise

Th

e A

larm

Rel

ay is

tota

lly in

depe

nden

t of '

SP'.

The

alar

m is

ene

rgis

ed b

elow

'SP

' un

til 'S

L' is

reac

hed,

the

rela

y th

en d

e-en

ergi

ses.

Ala

rm O

ff

OLE

HLE

LLE

SSPE

OLD

E

HLD

E

LLD

E

SSPD

E

-

CO

DE

000

001

002

003

004

005

006

007

008

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 5 OTHER CONTROLS DESIGN

Section 5 Page 1

SECTION 5 OTHER CONTROLS DESIGN

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 5 OTHER CONTROLS DESIGN

Section 5 Page 2

OTHER CONTROLS

When specified Lanemark can supply and buildother controls into the control panel to suit theapplication. Typical additional controls are :-

1. Time switches2. Hours run meters3. Liquid level controls4. Fan motor controls ( overload / contactor )

PROGRAMMING/SETTING OTHER CONTROLS

For controls like time switches a Data Sheet will becontained in this section of the manual givinginstructions on how to set and programme them.

INSTALLING / WIRING OTHER CONTROLS

When supplied with a burner the wiring will beshown in the specific wiring diagrams contained inthis manual.

Additional field wiring may be needed e.g.connection of a liquid level float switch.

Data sheets will be contained in this section of themanual giving details of any installation needed.

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

Section 6 Page 1

SECTION 6 GAS TRAIN DESIGN

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

Section 6 Page 2

GAS TRAINS

Gas trains are designed by Lanemark to meet thespecific application and customer requirementse.g.

1. Type and volume of gas2. Voltage ( 110V or 230V )3. Class of IP protection required4. Destination Country5. Special features e.g. pressure switches6. Modulating gas valve motor requirement7. Fine filters for some countries supplies

Gas trains are suitable for a maximum inletpressure of 100 mbar / 40 in.wg and IP54 unlessspecifically ordered to a different specification.

Lanemark will be pleased to advise on specialpressure requirements and supply special pressureregulators to suit.

The gas trains on TX15 to TX40 are normallysupplied prefitted to the burner body by a union( but removed for transport ) so that they canrotated on the union to face left or right.

Alternatively the TX15 to TX40 gas trains can beordered with the gas train loose for final connectionand installation on site within 2.5 m / 10 feet of theburner body. The TX60 gas trains are too large andheavy to be preconnected to the burner body andthey are always supplied loose. The installer willhave to supply a suitable piece of pipe and fittings,including a union, so the burner can be removed ifever needed.

Gas trains are generally designed to have a startrate ( also low fire ) of no more than 30% of themain ( high fire ) gas rate.

WIRING GAS TRAINS

The gas train’s gas valves are electricallyconnected back to the burners control panel.Lanemark generally make this wiring connectionand run it in a 3 m flexible PVC conduit. It isdisconnected for transport and has to be remadeon site. The cable cores are tagged and identifiedto aid reconnection.

The connections are also shown in the wiringdiagram contained in this manual if the manual wasdespatched with a burner.

DRAWINGS OF GAS TRAINS

If this manual was sent out with a burner a copy ofthe gas train drawing will be included in this sectionof the manual. The gas train drawing number is onthe burner’s Data Plate and a copy of this DataPlate is stuck in the front of this manual.

SETTING / ADJUSTING GAS VALVES

The gas train drawing will show the type of gasvalves used. Data sheets for the gas valves andother gas components like modulating motors willbe contained in this section of the manual. Thesedata sheets will show the basic adjustments thatcan be made.

LANEMARK INTERNATIONAL BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

Section 6 Kromschroder VCD Gas Valve

KROMSCHRODER VCD VALVE 1” Gas Train General Layout 1½” Gas Train General Layout

Note: All gas trains are supplied with a Low Gas Pressure Switch as standard.

DG40 (5-40mBar)

GAS FLOW

Bypass Valve VAS1

Main Valve 1VAD240R

Main Valve 2 VAS240

Main Valve 1VAD125R

Main Valve 2 VAS125

GAS FLOW Bypass

Valve VAS1

LANEMARK INTERNATIONAL BURNER MANUAL SECTION 6 GAS TRAIN DESIGN

Section 6 Kromschroder VCD Gas Valve

KROMSCHRODER VCD VALVE Valve Adjustment Technical Specification VAS Solenoid valve for VAD Constant Pressure Governor safe-guarding gas. for modulating burner IP65 IP65 Inlet Pressure PE: 10-500mBar Inlet Pressure PE: 10-500mBar Outlet Pressure PG: 2.5-25 mBar VAS The markings on the cover cap can be used for coarse adjustment of the flow rate. A 2.5mm Allen key

should be used, 1 turn is equivalent to 0.75mm valve stroke to a maximum of 5 turns.

VAD The outlet pressure PG is set to 10mBar by the factory. Adjust the pressure to that required using a

manometer on PG, with a 2.5mm Allen key on the Governor adjustor.

PL shown top right is the connection for the air control line.

PL PG

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 8 COMMISSIONING

Section 8 Page 1

SECTION 8 COMMISSIONING


Section 8 Page 2

PRECOMMISSONING ELECTRICAL THE BURNERS CONTROL PANEL

THIS APPLIANCE MUST BE EARTHED

These tests can only be carried out by suitablyqualified electricians.

Carry out the following electrical safety checksusing a multimeter. Do not use a P.A.T ( portableappliance tester ) as high voltages generated coulddamage the electronics in temperature controllersand the Satronic ( or alternative ) Control Box andgive a false reading.

Earth Continuity Check

1. The appliance must be disconnected from themain supply.

2. Set the multimeter to Ohms x1 scale and zero if

necessary. 3. Measure the resistance between the earth

connection point in the burners junction box andthe earth connection point from the supply panelor distribution board.

4. If the resistance is greater than 0.1 Ohm then

check that the earth cable size is adequate andthat all connections are clean, sound andcorrectly made.

Short Circuit Check

1. The burner must be electrically disconnectedfrom the main supply and the burners ownON/OFF switch must be On and anytemperature controllers or time clocks interlinkedshould be calling.

2. Set the meter to the Ohms scale x1 and

measure the resistance between the incominglive and neutral terminals in the burners junctionbox. If the meter reads zero then there is a directshort circuit and a fault that should be rectified.

3. Set the meter to Ohms x100 scale and measure

the resistance between the burners earthconnection point and the its incoming liveterminal. If the resistance seen is less thaninfinity then there is a fault that requiresrectifying.

Polarity Check

Connect the burner control panel to the incomingsupply set the meter to read AC Volts by 300Vscale.

If an isolating or step down transformer has beenused the secondary side must be end tapped andnot centre tapped as this can interfere with theoperation of the Satronic programmer.

1. Measure the voltage between the incoming liveand neutral terminals in the burners junction boxand it should read typically 230V AC or 110V asappropriate. The Satronic control box hasunder/over voltage protection and will not run ifthe supply is incorrect.

2. Measure the voltage between the incomingneutral and the earth connection in the burnerselectrical junction box and the voltage shouldread less than 15V AC.

3. If these voltages are not seen than a neutralfault or polarity fault may exist. If very sensitiveearth leakage trips have been fitted to theelectrical installation then some types of multimeter may cause them to trip while attempting tomeasure voltages to earth.

Resistance to Earth Check

1. The burner must be electrically disconnectedfrom the main supply and the burners ownON/OFF switch must be On and anytemperature controllers or time clocks interlinkedshould be calling.

2. Set the meter to Ohms x100 scale. 3. Measure the resistance between the incoming

live connection and the earth connection in theburners electrical junction box. The readingshould be infinity and if there is any otherreading then there is a fault which should beisolated and rectified.

PRECOMMISSIONING ELECTRICAL THE BURNERS 1 OR 3 PHASE FAN

1. Generally the connections will be checked in asimilar way as given previously. Look for 230V toneutral on 1 phase and 400V between phaseson 3 phase motors.

2. For 3 phase motors use the manual button onthe motor contactor or similar and check themotor is rotating in the correct direction. If notisolate and reverse two of the phaseconnections.

3. For 1 and 3 phase motors set the overload ormotor protection device in accordance withmakers instructions and with reference to thefan motor kW rating and full load current.


Section 8 Satronic DMG Box Page 3

PRECOMMISSIONING GAS DMG BOX

The gas pipework system from the gas meter to theburner should be sound and purged in accordancewith the standards given previously. A Test andPurging Certificate will be available to show this wascompleted. With the gas isolated at the main inlet,main gas train outlet ( and pilot line outlet isolatingvalve if fitted ) undertake the following checks to provethat the gas train valves are sound and have not beendamaged in transit :-

1. With reference to the gas train schematic drawingfit a manometer to the inlet pressure test nipple.2. Open the main isolating gas cock briefly and thenclose it. The gas trapped between the main isolatinggas cock and the first main valve seat should remainat constant pressure for 2 minutes. If loss of pressureis seen then the main valves or the pilot bypass gasvalve seats are letting by and it is faulty and must bereplaced as given later under Maintenance. Replaceall test nipples.

DRY RUN OF BURNER

With the main inlet gas isolating cock turned off andthe burners own on/off switch turned off which islocated on the burners electrical junction box completethe following checks :-

1. Ensure that the tank or bath is put into operationwith any recirculating pumps, agitators orautomatic make up systems running. The burnersexhaust fan should be running. This fan may havebeen wired back to the burner to get its start signalor it may receive a start signal from anindependent main motor control panel.

2. Switch on the burners on/off switch and anyisolators and the Satronic DMG970 control boxshould start to run. The red neon in the resetbutton will start to flash the following normal startup sequence :-

3. If the box was left at Lockout previously the neonwill glow red for 10 seconds followed by thelockout code :-

and this should be reset by pressing the button aroundthe flashing neon or using the reset switch on theburner. The switch has to be held for at least 1second.

The Satronic box should lockout at “air proving switchtime-out“ because the air pressure switch was set tomaximum before despatch to ensure only competentengineers put the burner into operation. Reset thelockout and turn the air pressure switch down to say 5m.bar ( but NOT to minimum because the Satronicbox can misinterpret this as a faulty pressure switch ).If a genuine air pressure switch lockout now occursbecause the switch has failed to detect that the fan isrunning investigate as given later under Fault Finding.

4. The Satronic box will normally run to the ignitionstage. Here the pilot gas valves will open ( gasshould be OFF for dry run ) and the ignition sparkwill attempt to light the pilot. At this stage theSatronic box will lockout due to “lockout safetytime” due to no pilot flame being present.

If the Satronic control box has run to this stage andlocked out then the burner is ready for commissioningof the gas and combustion.

IN THE UK COMMISSIONING OF GASAPPLIANCES CAN ONLY BE CARRIED OUT BYSUITABLY QUALIFIED TECHNICIANS WHO WILLBE C.O.R.G.I AND ACOPS REGISTERED TO DOTHIS WORK. FOR OTHER COUNTRIES LOCALREGULATIONS MUST BE OBSERVED.



COMMISSIONING COMBUSTION DMG BOX

All burners are fired at works as part of the finalinspection procedure but final settings can only be seton site to suit a particular application.

A BURNER WILL START AND RUN BUT IN THE UKIT MUST ALWAYS BE COMMISSIONED BY ASUITABLY QUALIFIED TECHNICIAN WHO HASBEEN C.O.R.G.I AND ACOPS REGISTERED TO DOTHIS WORK. FOR OTHER COUNTRIES LOCALREGULATIONS MUST BE OBSERVED.

The following settings and checks should be madeafter the precommissioning procedure has beencompleted.

The main inlet gas isolating cock should be OFF andthe burner should be turned off at its own on/offswitch.

Air Pressure Switch and Flue Damper

1. The air pressure switch was despatched set tomaximum. This has then been turned down totypically 5 mbar during the precommissioningstage to allow the burner to run. If not do this nowbut do not set the pressure switch to minimumbecause the Satronic box may misinterpret this afaulty pressure switch.

2. The flue damper should be set to about 2/3 rdsopen as an initial setting to allow the burner to run.

3. The electrical link in the control panel ( 6 – 6aService Engineers low fire hold link ) should beremoved so that the burner will run on pilot only.

4. The burners on/off switch and any other externalcontrols should be brought on and the mainisolating gas cock should be turned on.

5. The burner will start to run and the Satronicprogrammer will start to flash as shown previouslyuntil the ignition stage is reached. If the gaspipework is not completely purged of air the burnermay lock out on the first few attempts at ignition. Iflockout does occur the cause should be found byinterpreting the lockout signal code or by using theSatronic Satropen to read the lockout code. ( Fullinstructions for the operation and use of theSatropen are contained later in this manual).

6. Once the pilot flame is established the Satronicbox would normally bring on the main gas but asthe electrical link 6 – 6a has been removed thesecond main valve coil will not be energised.

7. The pilot flame can be adjusted to give a reliableflame by adjusting the pilot gas rate adjusterscrew. ( The location of this adjuster screw isshown previously in this manual ). To comply withstandards it must not exceed 30% of the mainflame rate. The Satropen should be used to readthe flame strength signal. It should read 200% . Ifthe signal is less than this increase the gas rate.

Main Flame and Exhaust Flue Damper

8. Switch the burner off and replace the electrical link6 – 6a and turn the inlet ball cock 2/3 rds off. Fit amanometer to the gas pressure test point on theburner head. ( See the previous illustration in thismanual ). From the burners Data Plate ( or thegraphs contained in this manual ) obtain the gashead pressure required to set the burner on therequired rate.

9. Restart the burner and it will run to the main flamestage this time. As the burner runs to main flamewatch the gas head pressure rise andprogressively open the inlet gas ball cock and setthe main gas pressure on the main gas valvegovernor. ( An illustration of the adjuster position iscontained previously in this manual and there is aprotective dust cover over the adjuster screwproper ). To increase gas turn the governor screwclockwise and anticlockwise to decrease.

10. Once the gas pressure has been correctly set formain flame the combustion should be set toachieve :-

Natural Gas

Oxygen ( O2 ) 6.0 %Carbon dioxide ( CO2 ) 8.5 %Carbon monoxide ( CO ) 100ppm (maximum )

Propane Gas

Oxygen ( O2 ) 6.5 %Carbon dioxide ( CO2 ) 9.5 %Carbon monoxide ( CO ) 100ppm (maximum )

A typical gross flue gas temperature is 190 - 220°Cwhen the system is up to its operating temperature.

The combustion is set by adjusting the position of theexhaust flue gas damper remembering to tighten thelocking nut when finished. Once the exhaust fluedamper is set pilot and main flame gas pressuresshould be rechecked as the position of the dampercan have a slight influence on the gas pressure.

11. The air pressure switch should be set when theflue and combustion system are cold and after theflue damper has been set. With the flue fanrunning but with the burner off measure thenegative pressure at the test point on the burnerbody ( as illustrated previously in this manual ).

The pressure switch should be set to typically 70% ofthe measured air pressure or 2 mbar less than themeasured air pressure. If the pressure switch is settoo high then there is a possibility that nuisancelockout could occur when detecting air pressure. If thepressure switch is set too low then there is thepossibility that the pressure switch would not switchthe burner off if there was a problem e.g. a partiallyblocked flue.



The pressure switch should never be set tominimum because the Satronic box times how longit takes the pressure switch to change over. If set tothe minimum it changes over so quickly the box canmisinterpret this as a faulty switch. A lockout codeof 99 on the Satropen ( an optional handheldreading device for the box ) shows that this is thecase. The Satronic box will not reset from thislockout.

An air pressure switch must never be set too lowto sacrifice safety for reliability.

12. Fit a manometer to the air pressure test point.With the burner running to the air prepurgestage the pressure switch should be turnedup to test that the air pressure switchprevents the burner from firing and that itlocks out after about 1 minute.

13. With the burner running the pressure switchshould be turned down and the burner shouldlockout due to loss of the air pressure signal.

14. With the burner running turn off the main gasisolating cock and check that the burner locksout due to loss of flame signal.

15. With the burner running in main flame the inletgas pressure should checked to ensure it iswithin specification :-

Natural Gas

100 mbar ( 40 in.wg ) maximum17.5 mbar ( 7.0 in.wg ) minimum and typical

Propane Gas

100 mbar ( 40 in.wg ) maximum35 mbar ( 14 in.wg ) minimum and typical

If the inlet pressure is above the maximum anadditional regulator must be fitted. If the inletpressure is below the minimum then the local GasSupply Authority should be contacted to establishthe cause. If the inlet pressure is unstable ( thepressure may fall at times of peak demand ) thenas the burner has been commissioned relative tothe standard inlet pressures problems may welloccur during periods of low pressure.

On Propane systems overpressure cut out withvents and under pressure cut out devices must befitted. The settings of these should be checked forsuitability and recorded.

If low inlet and high outlet gas pressure switcheshave been fitted these should be set and theiroperation checked. A low inlet gas pressure switchwill be set to 5 mbar below the minimum inletpressure specified above.

A high outlet gas pressure switch should typically beset to 3 mbar above the normal high fire gas

pressure. The slow opening adjuster on the maingas valve ( if fitted ) may need adjusting to slow theopening down or a pressure pulse may occur onnormal opening and trip the pressure switch.

Multiple Burners Sharing a Single Fan

16. Many burners will share a common exhaustfan and flue system. The individual burnersshould be first commissioned as for a singleburner. When all flue dampers and gasgovernors are set the gas pressures andcombustion settings should be rechecked withall burners running together and adjusted ifnecessary.

Modulating Motors

17. If a modulating motor is fitted to a ball valvethe motor end stop must be set so that when itis at its fullest closed position, there is stillsufficient gas flow, to light reliably and sustaina stable flame. The temperature controllershould be set and the correct response of themodulating motor to the control signal shouldbe checked. See the Data Sheet on the motorthat will be contained in this manual.

Final Checks

18. Check the operation of any mechanical orelectronic temperature controllers. Record theset points and for electronic temperaturecontrollers record the set-up parameters.Generally the burner should not be called tostart more than 6 times an hour and shouldnot switch from high flame to pilot / low flamemore than 60 times an hour.

19. Check the operation of any low liquid levelprotection systems or automatic liquid makeup systems.

20. Check that there is adequate ventilation forsafe combustion as given under designconsiderations previously.

21. The owner/operator of the burner systemshould be instructed in the basic operation ofthe burner and its controls.

FINALLY replace all pressure test points andcomplete a commissioning form similar to thesample contained in this manual.

IMPORTANT: IF FOR ANY REASON THECOMMISSIONING HAS NOT BEEN FULLYCOMPLETED OR IF THERE IS A PROBLEMWITH THE GAS SUPPLY , FLUE, VENTILATIONOR SAFETY CONTROLS THEN THE SYSTEMSHOULD NOT BE LEFT CAPABLE OF BEINGRUN. THE OWNER / OPERATOR OF THEBURNER SYSTEM SHOULD BE MADE AWAREBEFORE LEAVING SITE.


Section 8 Page 6 Natural Gas

Fig 1 NATURAL GAS – GAS PRESSURE AGAINST OUTPUT

CONVERSION:

1 kW = 3412 Btu/h 1 m.bar = 0.4 in.wg


Section 8 Page 6 Propane Gas

Fig 2 PROPANE GAS – GAS PRESSURE AGAINST OUTPUT

CONVERSION:

1 kW = 3412 Btu/h 1 m.bar = 0.4 in.wg


Section 8 Page 7

EXAMPLE OF TX BURNER COMMISSIONING REPORT FORM

CUSTOMER NAME: …………………………………………………………………………………………………..…………SITE ADDRESS: …………………………………………………………………………………………………………….….

BURNER MODEL: ……………………SERIAL No: ……………………… GAS TYPE: ……………………….……….CONTROL PANEL VOLTAGE:……………V GAS TRAIN TYPE: …………………………….………………...……..BURNER MOTOR POWER …………..….kW VOLTAGE:……..………V RUN CURRENT:…….………….Amp( The above can be found on the burner data plate stuck to the burner body and also a duplicate may be stuck in the inside cover of this manual )

PRECOMMISSIONING CHECKS:

1 BURNER EARTHED:……………………………………………………………………….……………………….. Y / N2 BURNER CONTROL PANEL ELECTRICAL INSTALLATION CHECKED:…..……………………….…….. Y / N3 BURNER FAN MOTOR ELECTRICAL INSTALLATION CHECKED:……………………………………….… Y / N4 FAN MOTOR CURRENT COLD :……………………………………………………………………………….…Amp5 FAN MOTOR CURRENT HOT: …………………..…………………………………………………………………Amp6 FAN MOTOR OVERLOAD SET ( COLD ) TO: ……………………………………………………………………Amp7 GAS INSTALLATION SOUNDNESS TESTED AND PURGED:………………………………………………. Y / N8 BURNER GAS TRAIN SOUNDNESS TESTED:………………………………………………………………… Y / N9 BURNER DRY RUN COMPLETED:………………………………………………………………………………. Y / N

COMMISSIONING CHECKS

1 AIR DAMPER SETTING % OPEN2 PRESSURE BEFORE DAMPER COLD m.bar3 PRESSURE BEFORE DAMPER HOT m.bar4 AIR PRESSURE SWITCH SETTING m.bar5 AIR PRESSURE AT BURNER HEAD GAS PRESSURE TEST POINT m.bar

PILOT FLAME SETTINGS

1 PILOT BURNER HEAD PRESSURE m.bar3 FLAME SIGNAL ( % or microamps )

MAIN FLAME SETTINGS

1 BURNER HEAD PRESSURE m.bar2 FLAME SIGNAL ( % or microamps )3 OXYGEN O2 %4 CARBON DIOXIDE CO2 %5 CARBON MONOXIDE CO %6 NET FLUE GAS TEMPERATURE °°°°C7 PROCESS TEMPERATURE °°°°C8 GAS FLOW RATE M3/h

OTHER

1 TEMPERATURE CONTROLLER SET POINT °°°°C2 TEMPERATURE CONTROLLER ALARM POINT °°°°C3 FLUE AND VENTILATION SATISFACTORY Y/N

NOTES:

SIGNED: FOR: DATE:

LANEMARK INTERNATIONAL TX MANUAL SECTION 8 COMMISSIONING

Section 8 Page 8

SATRONIC SATROPEN INSTRUCTIONS

LANEMARK INTERNATIONAL TX MANUAL SECTION 8 COMMISSIONING

Section 8 Page 9

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 9 MAINTENANCE

Section 9 Page 1

SECTION 9 MAINTENANCE


Section 9 Page 2

CLEANING AND MAINTENANCE

MAINTENANCE IN THE UK CAN ONLY BECARRIED OUT BY SUITABLY QUALIFIEDTECHNICIANS WHO WILL BE C.O.R.G.I ANDACOPS REGISTERED TO DO THIS WORK. FOROTHER COUNTRIES LOCAL REGULATIONS MUSTBE OBSERVED.

Maintenance should be carried at intervalsdepending on the hours run and the application ofthe burner. For burners running continuously thiscould be up to four times a year but never less thanonce a year.

CLEANING THE BURNER HEAD ASSEMBLY

1. Isolate the gas supply at the service gas cockprovided as part of the gas train. Isolate allelectrical supplies to the burner and its flue fan.

2. Remove the back cover plate from the burnerbody. Disconnect the ignition and flamedetection leads from the electrodes set taking anote of which is which.

3. Break the union to the burner head and removethe complete burner head assembly. See Figure1 Burner Head And Electrode.

4. The burner will typically have a light covering ofdust on the head and the perforated flame tube.This should be removed with a lint free rag or asoft brush and vacuumed up if necessary. Thisdust should be treated with care. A disposablemask and safety goggles should be worn toprevent the possibility of inhaling this dust orgetting any dust in the eyes.

5. The burner electrode set should be checked fortheir serviceability and generally they will bereplaced yearly.

6. The electrodes should be set as shown in thedrawing contained in this manual. See Fig 2Electrode.

7. Replacement of the burner head assembly is thereverse of the above.

8. After each service visit the integrity of the gassafety valves and the soundness of any gaspipework disturbed must be shown to be safe,as given previously under PrecommissioningGas. The burner settings must be checked asgiven previously under Commissioning and awritten record made.

CLEANING THE FAN

1. The fan will not normally require cleaning.

GAS TRAIN AND CONTROLS

The following checks should be made annually.

1. The operation and soundness of the isolatinggas cocks on the gas train should be checked.This should be done by pressure testing up tothe seal of these ball valves and establishingthat there is no loss of pressure in a similar wayto that used for testing the main gas valve seats.

2. The gas soundness of the gas train gas valvesand associated pipe work should be checked asgiven previously under Precommissioning Gas.

3. The setting of the air pressure switch and thelockout function of the burner’s control box to anincorrectly set pressure switch or lack of pilotstage start gas should be rechecked. Thisshould be done as given previously underCommissioning Dry Run.

4. The gas train and control panel should bevisually inspected to look for obvious signs ofdamage or deterioration.


Section 9 Page 3

FiG 1 BURNER HEAD AND ELECTRODES


Section 9 Page 4

Fig 2a ELECTRODE SETTINGS TX15 to TX40

Fig 2b ELECTRODE SETTINGS TX60

TX15/20 = 15mm TX25E/40 = 25mm

3 - 4 mm GAP

TX60 = 20mm

3 – 4 mm

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 10 FAULT FINDING

Section 10 Page 1

SECTION 10 FAULT FINDING

LANEMARK INTERNATIONAL TX MANUAL SECTION 10 FAULT FINDING


FAULT FINDING GENERAL DMG BOX

SYMPTOM FAULT ACTIONBurner Satronic control box at lockoutor not attempting to start.

Burner fault or safety interlock holdingthe burner off.The supply voltage is above/below thenominal supply voltage value ( 110 or240V ) and the Satronic box will notoperate.The remote burner lockout reset inputsignal ( 110 or 240V ) from anexternal panel is picking up inducedvoltage of sufficient size to becontinuously resetting the box.

Refer to the later section specificallyon burner control faults.Correct the supply voltage.

Screen the input cable or tie the resetelectrical terminal to neutral by asuitable resistor that can be suppliedby Lanemark.

Process temperature rising above therequired temperature.

Thermostat is set incorrectly.Thermostat is not sensing arepresentative process temperature.Thermostat is not switching down tolow fire or modulating downwards.

Reset thermostat.Check the actual temperature in thearea of the sensor.Check the wiring and settings ofelectronic controls and replace ifnecessary.

Process temperature fails to reach therequired temperature.

Thermostat is set incorrectly.Thermostat is holding burner in lowfire or not modulating upwards.

The burner performance has not beenmatched to the process requirement.The process conditions have beenchanged since commissioning.

Reset thermostat.Check the wiring and settings ofelectronic controls and replace ifnecessary.Recommission the burner.

Recommission the burner.

Evidence of poor combustionconditions e.g. sooting or smells.

Original commissioning settings havebeen altered.Do not use equipment

Recommission the burner.

FAULT FINDING TEMPERATURE CONTROLLERS

SYMPTOM FAULT ACTIONBurner runs to ignition and thetemperature controller switches theburner off and it attempts to cycleagain.

The ignition spark is interfering withthe electronics of the temperaturecontroller.

Check that the ignition spark plug capis an original part or replacement andsuppressed with a 5 kilo ohm resistor.

FAULT FINDING GAS VALVES

SYMPTOM FAULT ACTION1st valve or governor will not open. High pressure gas trapped between

1st and 2nd main valve seats andlocking up 1st valve.

Remove test point between seats.Tap valve to release 1st valve seat.Open up by-pass valve to allow moregas to flow.

2nd main valve not opening. The throughput restrictor has beenfully or almost fully closed. The slowopening adjuster is set to the slowestopening.

Open up the through put restrictor andincrease the speed of lift of the slowopening adjuster.

No pilot/start gas. The adjuster on the pilot / start gasvalve closed or nearly fully closed.

Use the adjuster to increase thepilot/start gas flow.



FAULT FINDING BURNER CONTROLS SATRONIC DMG970 PROGRAMMER

The burner faults can be diagnosed by looking atthe flashing neon on the Satronic programmer andinterpreting these using the codes shown below.Alternatively the flashing codes can be interpretedby using the Satronic Satropen which interprets theflashing code for you. ( See the separate section inthis manual on the Satropen ). Alternatively aPalmPilot hand held computer with infrared linkand special software can interpret the flashingcode. All lockout signals start with the neon beingcontinuously lit for about 10 seconds followed by aseries of flashes similar to Morse code that givesthe reason for lockout.

Fig 1 SATRONIC NORMAL RUN CODES

Fig 2 SATRONIC FAULT CODES



SYMPTOM FAULT ACTIONBurner will not run andprogrammer is not at lockout.Programmer is not flashing anysignal.

No power supply to the controller. Check terminal 9 in the base ofthe controller is at 110V or 230VAC. Check for external controlsholding burner off.If voltage OK – replace box.

The burner will not run andprogrammer will signal low mainsvoltage by 1 x short the 2 x longpulses followed by 1 x long pause.

Low mains voltage. Correct mains voltage.Until voltage is corrected switchthe burner OFF as a precautionas if voltage corrects itself theburner will automatically start.

Burner at lockout and will notreset.

Control box is faulty. Check for electrical short circuitsas given previously underPrecommissioning Electricalthen replace box.

Burner at lockout which whenreset goes to lockout again atSatropen 99 then 7 ( 2 x longpulse then 3 x short pulse ).

The programmer thinks the airpressure switch has stuck in thenormally open position or thepressure from the flue is sufficientto keep the switch in this position.However the switch is definitelymoving from n/c to n/o correctly.

Check the setting of the airpressure switch. If set toabsolute minimum it can changeover so quickly that theprogrammer believes it has stuckin the n/o position.Turn the switch up and reset toclear this fault.

Burner at lockout at Satropencode 32 ( 2 x short pulses then 3x long pulses then 1 long pausethen 5 x long pulses )

Satrocom gives short lockout.

The lockout reset button on theprogrammer has been pushed orthe external lockout reset facilityhas been used when the burner isnot at lockout.Once a lockout has been reset thebox locksout for a second time atshort lockout which automaticallyresets itself. This 2nd lockout lastseveral seconds and is to give theair pressure switch chance toreturn to the normally open positionbefore the box attempts to startagain. Normally the air pressureswitch will return to n/o so quicklythat this 2nd lockout with anautomatic reset will not be noticed.

Release lockout reset.

Check air pressure switch hasreturned to normally openposition after lockout reset.

Burner at lockout. Satropen code2 ( 2 x short pulse then 3 x longpulse ).

Programmer thinks there is a falseflame signal from the UV cell,infrared flame detector or from theionisation probe.

Check that gas valves are closedand no flame present.For UV or infrared detectorscheck that it is not seeinganother source of flame e.g. asecond burner in the same oven.Check wiring and for ionisationprobe check that it is not shortingto earth.



SYMPTOM FAULT ACTIONBurner starts ( you will see 2 xshort pulses then 1 x short pausewhich is 60 second wait for airproving switch to change over )then lockout at Satropen 3 ( 3 xshort and 2 x long pulses ).

The air pressure switch has notdetected that the burner fan isrunning and moved across to thenormally open position.

The 2 off 3 way air valves are notbeing energised and closing thevent to atmosphere.

Faulty air pressure switch or settoo high.

Check that the fan motorauxiliary contact has pulled in.Check that the air pressureswitch contacts are changingacross.

Use a manometer to check theactual air pressure seen at thepressure switch.

Check pressure being seenadjust and replace if necessary.

The programmer should now runthrough :-

Prepurge 40 seconds( 3 x short pulses then 1 x shortpause ).

Preignition 3 seconds( 4 x short pulses then 1 x shortpause )

Ignition safety time 3 seconds( 1 x long then 1 x short pulsefollowed by 1 x short pause ).

Listen / look for start valvesopening and ignition spark hissing.

Burner locks out on Satropen code1 ( 1 x short pulse then 4 longpulses ). Pilot flame was not seen.

Failure to establish pilot flameduring ignition sequence.

Use a manometer to check thatgas pressure is present as thepilot stage valves are opened.If there is too much air on ( theair damper too far open ) orinsufficient start gas for acorrectly set air damper then theair/gas mixture may not light.Check that an ignition spark ispresent. It may be possible tosee the blue glow from the sparkthrough the sight glass or hearthe hiss of the spark.



SYMPTOM FAULT ACTIONBurner locks out on Satropen code1 ( 1 x short pulse then 4 longpulses ). Pilot flame was seen.

The pilot flame has lit but the boxhas not detected it.

For an ionisation probe checkthe detection probe or wiring arenot shorting out.For a satisfactory flame signalthe Satropen will give a signal of200% ( but this will not be seen ifthe control box is at lockout ).Put a microammeter in serieswith the flame detection circuitand look for at least 2microamps DC ( not AC ) as asatisfactory flame signal. Thecommon should be towards theprobe and the positive towardsthe Satronic box.For UV cells or infrareddetectors, check the wiring,adjust the sensitivity, or replacethe detector as appropriate.These detectors must be fullyhome in their mounting collarwhich pulls in a miniature switchto show they are correctly fitted.Try changing the box.

Burner starts and pilot flameestablished.The box waits correctly for 12.5seconds to delay to moving tosecond stage ( 1 x long and 2 xshort pulses ) then locksoutimmediately or some time after themain flame is established.Lockout code on Satropen 9 ( 4 xlong then 1 x short pulse ).

Lockout code on Satropen 4 ( 4 xshort then 1 x long pulse ).

The flame signal may have beenlost as the main valves areopening and lifting off the pilotflame.

The air pressure switch hasopened during normal running.

For a satisfactory flame signalthe Satropen will give a signal of200%. Put a microammeter inseries with the flame detectioncircuit and look for at least 2microamps DC ( not AC ) as asatisfactory flame signal. Thesignal should be stable and notdipping below 2 microamps.Put a manometer on the burnerhead test point and look for thegas pressure increasingprogressively. If the pressureincreases rapidly as the mainvalve opens check forexcessively high inlet gaspressure and the operation ofthe governor.Check that the flame detectionprobe is positioned as given inthis manual.Use a manometer to observe theair pressure being seen by theswitch and adjust the switchsetting if necessary.

The programmer will signal normalrunning by 1 x long then 1 x shortthen 1 x long then 1 x short pulsefollowed by 1 x short pause.

Normal running.


Section 10 Page 7

NOTE: If the fault persists and the cause cannot be isolated , contact LanemarkInternational Ltd to arrange for a visit by one of our Service Engineers.

Lanemark International Ltd,Whitacre Rd,Nuneaton,Warwickshire.CV11 6BW

Tel: 024 7635 2000Fax: 024 7634 1166

Tel Int: + 44 (0) 24 7635 2000Fax Int: + 44 (0) 24 7634 1166

Web site : http://www.lanemark.come-mail : [email protected]

http://www.lanemark.com/

mailto:[email protected]

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 11 COMPONENT REPLACEMENT

Section 11 Page 1

SECTION 11 COMPONENT REPLACEMENT

LANEMARK INTERNATIONAL TX MANUAL SECTION 11 COMPONENT REPLACEMENT

Section 11 Page 2

COMPONENT REPLACEMENT

COMPONENT REPLACEMENT CAN ONLY BECARRIED OUT BY SUITABLY QUALIFIEDTECHNICIANS WHO WILL BE C.O.R.G.I ANDACOPS REGISTERED SPECIFICALLY TOUNDERTAKE WORK ON INDUSTRIAL GASBURNERS

ONLY ORIGINAL EQUIPMENT SPARESSUPPLIED BY LANEMARK INTERNATIONALSHOULD BE FITTED TO THESE BURNERS TOENSURE THE SAFE AND CORRECTOPERATION OF THE BURNER.

ISOLATE THE GAS SUPPLY AT THE SERVICEGAS COCK PROVIDED AS PART OF THE GASTRAIN. ISOLATE ALL ELECTRICAL SUPPLIESTO THE BURNER.

IGNITION AND FLAME DETECTION PROBES

1. To replace the ignition and flame detectionprobe set follow the instructions as givenpreviously in this manual under Maintenance –cleaning the burner head assembly.

BURNER HEAD ASSEMBLY

1. To replace the burner head follow theinstructions as given previously in this manualunder Maintenance – cleaning the burner headassembly.

FAN IMPELLER AND MOTOR

1. Generally this will not require replacing during aroutine service.

GAS VALVE COILS

1. Remove the electrical connections to the gasvalve by removing the push on plug caps or theconnections to the valve terminal blocks. Makea note of the position of the connections to aidreplacement later.

2. Remove the coil from the body of the gas valveby releasing the fixing nut or retaining clip onthe top of the gas valve. This fixing may belocated under a plastic cover.

3. Fit a new coil as the reverse of the above.Ensure that the replacement is the samevoltage as that removed.

4. After such work the integrity of the gas safetyvalves and the soundness of any gas pipeworkdisturbed must be shown to be safe, as givenpreviously under Precommissioning Gas. Theburner settings must be checked as givenpreviously under Commissioning and a writtenrecord made.

GAS VALVES BODIES

1. Remove the electrical connections to the gasvalves by removing the push on plug caps or theconnections to the valve terminal blocks. Make anote of the position of the connections to aidreplacement later.

2. Fit a temporary earth continuity connection andthen break the gas unions on the burner gastrain.

3. Remove the faulty gas valve body and replaceusing a new “O” Ring or replace pipework usinga proprietary gas jointing compound. Ensure thatthe direction of gas flow through the gas valve iscorrect by looking for the direction arrowstamped on the casting.

4. Replace the complete gas train assembly as thereverse of the above.

5. After such work the integrity of the gas safetyvalves and the soundness of any gas pipeworkdisturbed must be shown to be safe, as givenpreviously under Precommissioning Gas. Theburner settings must be checked as givenpreviously under Commissioning and a writtenrecord made.

LANEMARK INTERNATIONAL TX MANUAL SECTION 11 COMPONENT REPLACEMENT

Section 11 Page 3

BURNER PROGRAMMER

1. Release the fixing screw holding the BurnerProgrammer box ( Satronic, Landis, Honeywellor similar ) to its base and pull the box out.

2. Replace as the reverse of the above.3. The burner settings must be checked as given

previously under Commissioning and a writtenrecord made.

IGNITION TRANSFORMER

1. Release the live, neutral and earth electricalconnections from the ignition transformer.

2. Unscrew the ignition cable from the transformer.3. Release the fixing screws and remove the

ignition transformer complete.4. Replace as the reverse of the above. Care must

be taken that a good connection is made withthe ignition cable onto the transformer body.

5. The burner settings must be checked as givenpreviously under Commissioning and a writtenrecord made.

MODULATING MOTOR ( IF FITTED )

1. Remove the plastic cover over the motor andrelease the electrical connections. Note wherethese electrical connections go.

2. The shaft of the ball valve will have an indexmark. Note the position of this mark relative tothe clamp that grips it.

3. Release the clamp and the screws holding themotor body.

4. Turn the motor over and note how the splinedshaft is aligned relative to its indexing mark. AData Sheet for the motor is contained in thismanual giving more details of this. Note howthe small switches on the Printed Circuit Boardare set as these determine the direction oftravel and the type of control signal used.

5. Set the splined shaft and switches on the newmotor as per the old motor.

6. Refitting is the reverse of the above.7. The burner settings must be checked as given

previously under Commissioning and a writtenrecord made. In particular the bottom end stopof the modulating motor must be set sufficientlyopen to allow enough gas to pass for reliablestarting of the burner.

3 WAY AIR VALVE

1. Release the electrical plug cap from the coil ofthe valve.

2. Release the retaining nut from the stem of thevalve and the coil can now be lifted away.

3. If the valve body itself is faulty the body can bereleased from the plastic tubes by releasing thepush on pipe connections. A screwdriver shouldbe used to push the collars inwards then thepipe can be pulled out.

4. Release the valve body if necessary by releasingthe backnut holding the valve to the backplate.

5. Replace as the reverse of the above.6. If the 6mm plastic pipes have been disturbed

care should be taken that these have beenreplaced correctly and a good air tight sealmade.

7. The burner settings must be checked as givenpreviously under Commissioning and a writtenrecord made.

AIR PRESSURE SWITCH

1. Remove the plastic cover over the pressureswitch and release the electrical connectionsand the switch fixing screws.

2. Replace as the reverse of the above.3. The burner settings must be checked as given

previously under Commissioning and a writtenrecord made.

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 12 SPECIAL FEATURES

Section 12 Page 1

SECTION 12 SPECIAL FEATURES

If any Special Features were designed and supplied with a burner details will be containedin this section. This could be Data Sheets for special components and additional operatingand commissioning instructions.

LANEMARK INTERNATIONAL TX MANUAL SECTION 12 SPECIAL FEATURES

Section 12 Page 2

SPECIAL FEATURES If any Special Features were designed and supplied with a burner details will be contained in this section. This could be Data Sheets for special components and additional operating and commissioning instructions.

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 13 RECOMMENDED SPARES

Section 13 Page 1

SECTION 13 RECOMMENDED SPARES

If this manual was sent out with a burner then the Recommended Spares list will becontained in this section of the manual for the burner and any accessories e.g.Temperature Controllers.

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 14 HEALTH AND SAFETY

Section 14 Page 1

SECTION 14 HEALTH AND SAFETY

LANEMARK INTERNATIONAL TX MANUAL SECTION 14 HEALTH AND SAFETY

Section 14 Page 2

C.O.S.H.H ( CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH )

The burner as delivered including packagingcontains no chemicals or substances that representa hazard to health during installation or operation ifinstalled in accordance with these instructions.

GASKETS

The gaskets as supplied as original equipment areceramic fibre with binder. They are pre-cut to shapeand prefitted to the burner. These gaskets do notneed cutting on site.For service work when fitting new gaskets, usegloves and protective goggles and do not allow thismaterial to come into contact with the skin, eyes orinhale or ingest it.

PAINTS

During first operation there may be a faint smell butif the burner is operated in an area ventilated inaccordance with this manual this represents nohazard.

SEALENTS

Gas tight joints are made with a proprietary gasjointing compound and no other chemical sealantsare used. Gaskets are fixed with silicone basedadhesive.

HEALTH AND SAFETY

The following should be considered when installing,operating or servicing this burner.

LIFTING

The weight of the burner and fan or heat exchangershould be assessed before lifting commences. Thegas train may be removed if necessary to reducethe weight of the burner and so aid safe lifting.Two persons may be required to lift larger fans andheat exchangers.Burners, fans and heat exchangers should not beleft unsupported.

SHARP EDGES

Any sheet metal edge that does not have a safetyedge or protective covering should be handled withgloves.

ELECTRICAL

THIS BURNER MUST BE EARTHED

The burner must only be installed and maintainedelectrically by trained competent electricians.

GAS

In the UK this burner must only be installed andmaintained by trained and competent technicianswho are C.O.R.G.I and ACOPS registeredspecifically for industrial gas burners. For othercountries local regulations must be observed.

RECYCLING

The burner is made from:

Mild and stainless steel sheet and tube.Aluminium / cast iron castings.Copper wire and windings.Plastic switches, terminals, controls etc.

These burners contain the minimum of welding andthey can easily be unassembled into their mainmaterial group. Approximately 95% by weight canbe recycled.

DISPOSAL OF PACKAGING AND BURNER

The cardboard box and polyurethane packing canbe recycled or disposed of to an appropriate facility.

The burner body can be stripped down and thematerials recycled or disposed of to an appropriatefacility.

Lanemark International Ltd would be pleased toreceive back by prior arrangement the burner or itspackaging for recycling.

LANEMARK INTERNATIONAL TX MANUAL SECTION 14 HEALTH AND SAFETY

Section 14 Page 3

FLUING TX BURNERS INSIDE BUILDINGS ‘Lanemark International Ltd recommends that flues should always discharge outside the building. However, there is no UK regulation, applicable in a factory that specifies this action. End users may decide it is safe to terminate the flue inside the building but only if they have carried out stringent risk assessments. The end user, as the employer of the operatives in the building, should take advice from the Health and Safety Executive, either directly or by reference to its publications e.g. Guidance Note EH22 ‘ Ventilation of the Workplace’.

Lanemark International’s Service Engineers are Approved Code of Practice Scheme (ACOPS) certified and Lanemark International is CORGI registered as required by UK law. If an end user has flues terminating inside a building, a Service Engineer may ask to see the relevant hazard assessments and HSE documentation before commencing work on the gas equipment. Such a request will be to reassure the Service Engineer, who has a legal obligation to take care of his own safety and that of others, that the area is considered safe and that he is complying with ACOPS regulations’.

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 15 NOTES

Section 15 Page 1

SECTION 15 NOTES

LANEMARK INTERNATIONAL TX BURNER MANUAL SECTION 15 NOTES

Section 15 Page 2

NOTES

CUSTOMER NAME: ………………………………………………………………………………………………………SITE ADDRESS: ………………………………………………………………………………………………………….

BURNER MODEL: ……………………SERIAL No: ……………………… GAS TYPE: ………………………….CONTROL PANEL VOLTAGE:……………V GAS TRAIN TYPE: …………………………….………………..BURNER MOTOR POWER …………….kW VOLTAGE:……………V RUN CURRENT:…………….Amp( The above can be found on the burner data plate stuck to the burner body and also a duplicate may be stuck in the inside cover of this manual )

DATE NOTES SIGNED

LANEMARK INTERNATIONAL TX BURNER MANUAL

L A N E M A R K I N T E R N A T I O N A L L T DL A N E M A R K H O U S E W H I T A C R E R D N U N E A T O N E N G L A N D C V 1 1 6 B WTel +44 (0)24 7635 2000 Fax +44 (0)24 7634 1166 e-mail [email protected] Web Site http://www.lanemark.com

Extra copies of this manual are available at £25.00 each + VAT. Please quote the Job Number on the front.

Documents

PROCESS BURNER DIVISION - Lanemark Burners/Product Manuals - English/TX... · PN 72001 OCT 2000 PROCESS BURNER DIVISION INSTALLATION, COMMISSIONING AND MAINTENANCE MANUAL The information