MOUNTING INSTRUCTIONS ZANTINGH BURNERINSTALLATION

Transcription

1 MOUNTING INSTRUCTIONS ZANTINGH BURNERINSTALLATION Op al onze leveringen en diensten aan Nederlandse (contracts)partijen zijn de FME-CWM voorwaarden van toepassing (gedeponeerd bij de Kamer van Koophandel te Den Haag). Op al onze leveringen en diensten aan niet-nederlandse (contracts)partijen zijn de Orgalime S 2000 voorwaarden van toepassing (gedeponeerd bij de Kamer van Koophandel en Nijverheid te Brussel).

2 LANGRIJK Beslist lezen! IMPORTANT read this first! This manual is an integral part of the product; it includes instructions for installation, commissioning and operation. Read instructions attentively! Manufacturers responsibility and warranty shall not apply if installation, commissioning, operation or maintenance is not in accordance to the regulations of this manual. Store this manual carefully! Content: page 1. INTRODUCTION 3 2. GENERAL 3 3. REGULATIONS 4 4. ASSEMBLY Mounting the burner ont the heat exchanger (boiler) Gastrain connections Pilot gas Measuring line Air connection Fan TR burner installation Fan RKB burner installation Oil connection Emergency oil high/ low Modulating on oil ELECTRICAL CONNECTION FUDUFACE LOWWATER SYR OIL DIAGRAMS PUTTING INTO OPERATION 23 ELECTRICAL DIAGRAMS 24 Page. 2

3 1. INTRODUCTION Dear Customer, We would like to thank you for your confidence in our organization and product. We provide this manual to ensure distribution of all the important information for your safety, optimal profit and product lifetime. We recommend you read this manual and instructions carefully before installing the Forced gas burner. In order to meet these objectives, installation, commissioning, operation and maintenance shall be carried-out in accordance to the instructions of this manual and local regulations. The safety and operating instructions must be followed. Our technical department can provide additional information and support. If you have any questions, please contact us. Phone general +31(0) Phone service +31(0) or 2. GENERAL The Zantingh burnerinstallation are made in two variants Variant 1 is the TR-monobloc-burnerinstallation. This burner is made for burner outputs of kw and with a maximum of kw this is the basic model of our burnerprogram. The burner and the fan are in this model directly linked to each other. The fan is equipped with a AC motor which will be regulated by the frequency drive. Variant 2 is the RKB-duobloc-burnerinstallation. This burner is made for burner outputs of kw and with a maximum of kw. The burner and the fan are in this model separated. The fan mounted on the ground and is connected to the burner with a flexible sleeve. Page. 3

4 3. REGULATIONS BELANGRIJK: IMPORTANT: Use a notified installer for mounting the burner installation. The instructions meet the applicable (local) standards and regulations. 4. ASSEMBLY 4.1 MOUNTING THE BURNER ON THE HEAT EXCHANGER (BOILER) Apply the dimensions of the burner drilling holes as instructed on the dimensional sketch for the burner and the instructions of the boiler supplier. Warning! For service purposes it is a must to have enough space on both sides of the burner installation. The quality of the bolts or stud bolts should be at least 8.8. The total thickness of the burner flange, packing and gasket amounts to approximately 38 mm. To simplify assembly on the boiler, the flange holes are hold wide enough. Washers should, therefore, always be used underneath the fastening bolt heads or nuts. Use gas fitter tape to tape around the fastening bolts to prevent corrosion of the bolts. Place a thin layer of silicone paste on the burner packing. The paste should be heat-resistant to temperatures of up to 190 ºC. Warning! Depending on the type of burner the fastening holes should be drilled pointedly or bluntly. Refer to the dimensional sketch for the type of burner that has to be assembled. Do not use the gasket for marking pruposes, because it is easily damaged. Page. 4

5 When de burner is mounted horizontal leveled the bolts can be tightened according to the above shown graphic. The burnerhead most always have brickwork and the burner head must always be 200mm beyond the brickwork, see graphic below. The boiler front should always have brickwork. In case of a water cooled front, the gap between the burner and boiler should be filled with brickwork. Ensure there are no materials, people or animals in the flue before placing the burner! Mount the burner section on the boiler. Use reliable lifting/hoisting equipment, which is at least capable of supporting the mass of the complete burner section. Attention! The center of gravity of the used crane hook is not always located above the center of gravity of the burner. If necessary, the burner section should be held horizontally using additional slings or supports while placing the boiler. Prevent damage to the packing. Replace the packing when it is warped or cracked! Page. 5

6 4.2 GASTRAIN CONNECTION Measure and mount the gas pipes without stress between the burner and the gastrain, according to local regulations, always respect local regulations. Diameter choice; diameter is equal to the burner connection or the gas street connection. If these diameters are not the same, choose the largest diameter of the two. The maximum allowed length of this section of piping is 4 meters. Connect the gas street to the gas pipes, the burner and the open air according to the gastrain diagram and local regulations. Attention! The diameter of the gas street does not determine the diameter of the gas pipes! Connect the supplied synthetic pipes and the cooling coil which may still have to be mounted to the connections marked PF and PL according to the gas street diagram. These synthetic pipes are to be mounted without bends and/or culverts. The gas pressure at the hand valve A1 should under no circumstances fall under or above the minimum and maximum values given in the technical specifications. Close A1 and bleed the gas street when testing the gas pipes to prevent damage to the gas street components due to high pressure. The inlet pressure on the gastrain cannot be higher than the below mentioned table: Designpressure Pmax Mbar Mbar This is the maximum pressure for the attached components so they won t get damaged. Page. 6

7 4.2.1 Pilotgas When the gastrain is positioned the pilotgas line has to be mounted. This is a 15 mm pipe from the gastrain to the burner, see below graphics Measuring line Also the measuring lines for the air pressure and the boiler furnace pressure has to be mounted. The measuring line has to be mounted with any nods and syphon effects. Mount the measuring line from the burner to the pneumatic gascontrol valve, see below graphics. For the combustion chamber pressure measurement there must be a socket ¼ " welded on the boiler front. The connection must have a free connector on the Furnace. This must therefore be drilled through the brickwork. Mount the cooling coil on the socket then connect the measuring line to the gasvalve. Page. 7

8 4.3 AIR CONNECTION Check if there are any loose (spare) parts in the fan casing. Place the fan and connect it to the burner using the supplied fitting piece with flexible section. Secure the fan, using vibration isolators, to a stable base to prevent that the position of the fan with regard to the burner changes due to sagging or shifting. The mounting length of the flexible section after assembly should be 10 to 20 mm longer than the original length. This is to absorb movement without damaging the flexible section. Attention: The fan may not be put into operation unless the outlet side is connected and the suction connection has a damper and/or the supplied safety grid. - The motor may overload if the counter pressure is not sufficient. - If the suction side is connected to a channel section, the fitter should ensure that everything is according to the machine guidelines and according to local regulations. The fitter has to produce a certificate stating this Fan TR burner installation. The burner and the fan are in this model directly linked to each other, see graphic below for connecting the fan to the burner installation. Page. 8

9 4.3.2 Fan RKB burner installation. The fan mounted on the ground and is connected to the burner with a flexible sleeve. Below the process on how to mount the fan under the burner: - Position the fan that the center of the outlet is placed below the center of the burnerinstallation. Then mark the holes of the fan on the ground. - Remove the fan and drill the drawn holes in the ground, depending on the vibration damper a hole of 8 to 10mm. - Mount the vibration dampers with the threaded end in the holes in the floor. - Place the fan on the vibration dampers and mount the fan on the ground with the delivered bolts. - Mount on the front side of the burner flange also a slice of band. - The sleeve needs to be mounted with the delivered counter flange on the burner flange. - Below is show how the fan and burner are mounted; Page. 9

10 When the Min. Height midpoint boiler furnace is too low the delivered inlet duct has to be mounted between the burner and the fan. When this is the case the mounting instruction are as follows; - Mount the inlet duct on the burner. - Mount the sleeve on the fan. - Position the fan that the center of the fan is placed in front of the inlet duct. Then mark the holes of the fan on the ground. - Keep approximately 80 mm between the fan and inlet duct. - Remove the fan and drill the drawn holes in the ground, depending on the vibration damper a hole of 8 to 10mm. - Mount the vibration dampers with the threaded end in the holes in the floor. - Place the fan on the vibration dampers and mount the fan on the ground with the pre delivered bolts. - Mount the sleeve on the inlet duct. - Below is show how the fan and burner are mounted; Page. 10

11 4.4 Oil connection The oil connections should always comply with local environmental requirements and applicable standards. Each oil system must have an oil filter present which is correct dimensioned for the capacity. For the consumption by type please see the burner manual. The oil pumps are not self-suctioning this means that the oil must be transported with an over excess pressure to the oil pump. This can be done by applying an above-ground tank with a bottom connection to the static pressure of the oil on the pump. Or you can choose for an oil supply pump. This pump mount at the oil tank which it under a small positive pressure of +/-0.5 bar brings to the oil pump. We also advise to make an oil buffer tank for the oil pump. This tank assures that no foaming and air bubbles come to the burner. There is also more likely to have a permanent static pressure on the oil pump. The Zantingh burner installations with oil is in different designs; - Emergency oil high/ low only. - Modulating on oil Emergency oil high/ low On the burner there will be an oil supply connection of 12mm. This connection has to be connected to the outlet of the oil pump. The oil pump can be delivered in different versions. The following versions are possible, see next page. Page. 11

12 Pompset for TR 0,37kW Danfoss S = Inlet R = Return P = Outlet(side) Pompset for RKB 0,55kW Delta IN = Inlet R = Return P = Outlet Pompset for RKB 0,55-5,5kW S = Inlet R = Return P = Outlet When the oil pump Outlet is bigger than the connection on the burner, the bigger diameter needs to be used. Just before the burner a conical pice need to be added from the bigger to the smaller pipe to connect the oil pipes Modulating on oil An modulating oil installation the burner also needs a return line. The return line must be brought back up to the oil tank which is placed next to the burner. On the picture below to see the connections of the burner. The left emanating from the control valve is the return. The right Jack is the inlet connection. Page. 12

13 5. ELECTRICAL CONNECTION Connect the burner, the gas street and the switch panel according to the electrical diagram (terminal block diagram with instructions) and the local regulations. Attention! When the fan is not visible from the operating position of the main switch, a disconnecting switch should be provided to guarantee safety during maintenance. Before testing the fan, check if the delivery connection is connected airtight to the burner and the suction side is provided with a damper and/or the supplied safety grid. The cooling fan for the motor may be used as an indication to check the direction of rotation. Attention! Never insert an object through the openings of the grid to determine the direction of rotation. Operate the relay for a short period of time. The cooling fan shall start to turn. The direction of rotation becomes easily visible as the number of rotations decreases. Please see page 16 until FIDUFACE The FIDUFACE is an interfacing between a (gas) burner installation and a greenhouse climate computer. The FIDUFACE is a result of a workgroup. Members of this workgroup: technicians representing the burner branche FIGO and the climate computer branch DICOTU. The FIDUFACE is no separate, standard interface or something like that, but an integrated switching in the burner panel. Because of that the FIDUFACE will be delivered by the burner manufacturer. The input and output concerning the electrical cables are standardized. The functions are standard as well. The advantage of this is that every burner equipped with FIDUFACE, is able to communicate with a computer with FIDUFACE output. The FIDUFACE also takes care that the burner will not do something wrong because of eventually incorrect computer signals. On the other end, the computer takes care about all kinds of control functions such as: burner on off; burner load and so on. The burner load control will be totally ignored than. However the burner always does check that no unsafe situation is created by the climate computer. Page. 13

14 In cases that the computer is unable to control the relevant control functions of the burner, the computer will give back the burner control functions to the burner itself automatically. In such a case the burner will control itself as stand-alone installation. The computer does control by means of the FIDUFACE the following functions: 1. Burner on or off. 2. Burnerload more or less or, burner load stays where it is. 3. feedback position. The burner does al kind of burner activities itself. The climate computer acts only like a kind of a PID temperature regulator. FIDUFACE SYSTEMS: The Zantingh burners can be delivered with 2 types of burner controls. Each type has his own Fiduface input signals. Type 1: is Zantingh burner with Autoflame Micro Modulation (MM) burner control. Burner type description: TR / RKB x.x ND MM Gas/Oil Burner control options are: Burner load controlled digital* (pulses) (standard) Burner load controlled analogue* (Voltage ) 0 10V / 2 10V (Voltage ) 0 5V / 1 5V Burner load controlled analogue* (Current) 0 20mA / 4 20mA * digital or analogue signal depending on climate computer, see page. Type 2: is Zantingh burner with Zantingh controller dtron 308H (P) burner control. Burner type description: TR / RKB x.x ND P Gas/Oil Burner control options are: Burner load controlled digital (pulses) (standard) Burner load controlled analogue (Voltage ) NOT AVAILBLE Burner load controlled analogue (Current) NOT AVAIBLE FIDUFACE connections For all the FIDUFACE input connections: Max. Current each input connection is 100mA with 24 volt AC or DC. Fuses for this are in the climate computer. The FIDUFACE itself is 24 volt AC and DC both. The potential free contacts of the FIDUFACE concerning the climate computer can be powered with max. 24 volt AC or DC 100mA. The inputs are galvanic separated. Page. 14

15 FIDUFACE connections with a Zantingh burner with Autoflame Micro Modulation (MM) burner control (type 1). Computer active / not active; Conn. 600 and 606 energised Computer does control the burner. Conn. 600 and 606 deenergized Burner controls itself. In the line 606 there also is the selection switch: Burner stand alone or burner externally on the computer. Burner on / off; Conn. 600 and 601 energised Conn. 600 and 601 deenergized Computer does switch on the burner. Computer does switch off the burner. Burner start ready; Conn. 610 and 611 closed Burner start is ready. Load controller can be activated. Conn. 610 and 611 open Burner start is not ready. Burner load Pulses; Conn. 600 and 603 energised(pulse) Burner load lower. Conn. 600 and 604 energised(pulse) Burner load more. Conn. 600; 603; 604 deenergised(pulse) Burner load no change. Burner load Voltage; Conn. 631 (voltage +) Burner load 0 10V / 2 10V*. Conn. 632 (voltage +) Burner load 0 5V / 1 5V*. Conn. 635 (zero) zero. Conn. 639 screen connection. * depending on dip switch settings, see page 3. Burner load Current; Conn. 600 and 633 (current) Burner load 0 20mA / 4 20mA*. Conn. 635 (zero) zero. Conn. 639 screen connection. * depending on dip switch settings, see page 3. OPTION: Start CO 2 / Flue gas valve; (if optioned) Conn. 605 energised Start CO2 or flue gas valve open. Page. 15

16 Feedback burner load Voltage; Conn. 640 (zero) zero. Conn. 641 (voltage) 0 5V / 1 5V*. Conn. 642 (voltage) 0 10V / 2 10V* Conn. 649 screen connection. Feedback burner load Current; Conn. 640 (zero) zero. Conn. 645 (current) 0 20mA / 4 20mA* Conn. 649 screen connection. FIDUFACE connections with a Zantingh controller dtron 308H (P) burner control (P) burner control (type 2). Computer active / not active; Conn. 600 and 606 energised Computer does control the burner. Conn. 600 and 606 deenergized Burner controls itself. In the line 606 there also is the selection switch: Burner stand alone or burner externally on the computer. Burner on / off; Conn. 600 and 601 energised Computer does switch on the burner. Conn. 600 and 601 deenergized Computer does switch off the burner. Burner start ready; Conn. 610 and 611 closed Burner start is ready. Load controller can be activated. Conn. 610 and 611 open Burner start is not ready. Burner load Pulses; Conn. 600 and 603 energised(pulse) Burner load lower. Conn. 600 and 604 energised(pulse) Burner load more. Conn. 600; 603; 604 deenergised(pulse) Burner load no change. Feedback burner load Pulses; Conn. 620; 621; 622 Potentiometer 1 KΏ mounted on the air shutter assembly. Conn. 623 screen connection. Potentiometer will be powered with max. 10 volt and 10 ma. OPTION: Start CO 2 / Flue gas valve; (if optioned) Conn. 605 energised Start CO2 or flue gas valve open. Page. 16

17 CHANGING FROM INPUT AND OUTPUT SETTINGS. Inside the control panel is a terminal strip X0. Depending on the input signal you have to make the right connections on this strip, see image and picture below. FIDUFACE connections with a Zantingh burner with Autoflame Micro Modulation (MM) burner control (type 1). Burner load Digital (Pulses); Connect terminal X0-1 and X0-2 for digital burner load control. (standard) Burner load Analogue (Voltage/Current); Connect terminal X0-2 and X0-3 for analogue (voltage) load control. Feedback burner load Voltage; Connect terminal X0-5 and X0-6 for calculated burner load feedback (standard setting) Connect terminal X0-4 and X0-5 for real time burner load feedback. Note: Burner is delivered standard with calculated burner load feedback. The best choice is to take a real time burner load feedback. But in many cases the climate computer controls to fast for this signal. If the climate computer can work with a slow feedback signal then the best option is to work with a real time feedback. Please check with you climate computer supplier which option is the best or possible. Dip switch settings: Inside the burner panel there are 2 signal converters form TITAN products, see picture below. One is for the input settings and the other for output settings. Behind the front cover there is an option switch. For voltage or current settings you need to change this switch. Page. 17

18 Inputs settings: Voltage; 0 10V Option switch 1 off, 2 off (standard) 2 10V Option switch 1 off, 2 on 0 5V Option switch 1 off, 2 off 1 5V Option switch 1 off, 2 on Current; 0 20mA Option switch 1 off, 2 on 4 20mA Option switch 1 on, 2 on Output settings: Voltage; Standard only 0-5V and 0-10V Current; 0 20mA Jumper on left top site to the right 2 pins 4 20mA Jumper on left top site to the left 2 pins Page. 18

19 7. LOWWATER SYR 2 Page. 19

20 9. DIAGRAMS Page. 20

21 Page. 21

22 Page. 22

23 9. PUTTING INTO OPERATION The putting into operation of the burner installation is the last link of the supplier's quality control and is, under all circumstances, only to be carried out by personnel who has been instructed and authorized by the supplier due to its specialist characteristics and the many possible configurations. The supplier accepts no liability if, and when, this requirement is not met. Page. 23

24 Page. 24

25 Page. 25

26 Page. 26

27 Page. 27

28 Page. 28

29 Page. 29

30 Page. 30

31 Page. 31

32 Page. 32

33 Page. 33

34 Impressum Alle rechten, ook vertalingen, voorbehouden. Niets uit deze uitgave mag worden verveelvoudigd, opgeslagen in een automatisch gegevensbestand, of openbaar gemaakt, in enige vorm of op enige wijze, hetzij elektronisch, mechanisch door fotokopieën, of op enige andere manier, zonder voorafgaande schriftelijke toestemming van Zantingh B.V.. Nadruk, ook als uittreksel is niet toegestaan. Druk- en zetfouten voorbehouden. Deze montage en gebruiksvoorschrift voldoet aan de technische eisen bij het in druk gaan. Wijzigingen in techniek en uitvoering voorbehouden. Page. 34